Service 3121180 12-03-12 Global English

Service and Maintenance Manual
Models
450A/AJ
Series II
Prior To
S/N 0300160835
P/N - 3121180
December 3, 2012
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS
A. GENERAL C. MAINTENANCE
This section contains general safety precautions which
must be observed during aerial platform maintenance. It is
of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
strict attention to these warnings and precautions to avoid THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
possible injury to themselves or others, or damage to the NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure machine is safe to operate. • WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT
WHEN WORKING ON MACHINE.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT- IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION COMPONENTS.
FROM THE MANUFACTURER. • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
The specific precautions to be observed during mainte- SECURE AT ALL OTHER TIMES.
nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
when servicing hydraulic and larger machine component FORMING ANY MAINTENANCE.
parts. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
Your safety, and that of others, is the first consideration TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
when engaging in the maintenance of equipment. Always CAUGHT ON OR ENTANGLED IN EQUIPMENT.
be conscious of weight. Never attempt to move heavy • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
parts without the aid of a mechanical device. Do not allow MACHINE AND IN SERVICE AND OPERATOR MANUAL.
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
is provided. SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT
SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- • NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCK-
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER- ING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN
ATOR. ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORM-
B. HYDRAULIC SYSTEM SAFETY ING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CON-
TROLS.
It should be noted that the machines hydraulic systems
• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING
operate at extremely high potentially dangerous pres-
REPLACEMENT OF ELECTRICAL COMPONENTS.
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED
the system. IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NON-FLAMMABLE CLEANING SOLVENTS.
3121180 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue - January 24, 2003

Revised - March 14, 2003
Revised - August 26, 2005
Revised - February 15, 2006
Revised - March 14, 2007
Revised - October 10, 2007
Revised - December 22, 2010
Revised - November 1, 2012
Revised - December 3, 2012
A-2 – JLG Lift – 3121180

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Specifications and Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.7 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.9 Pressure Settings - PSI (BAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.10 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.11 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.12 Draining Propane Regulator Oil Build Up (Prior to S/N 0300137808) . . . . . . . . . . . . . . . . . . . . . .1-11
1.13 Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.14 Propane System Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
SECTION 2 - GENERAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
3121180 – JLG Lift – i

TABLE OF CONTENTS

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
DO the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
DO NOT Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Pneumatic Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Polyurethane Foam Filled Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Solid Flex Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Torque Hub (Machines Built Before S/N 0300071527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Roll, Leak, and Brake Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Housing-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Spindle-Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Output Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Spindle-Brake Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Housing-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
DW2B INTEGRAL BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.3 Torque Hub (Machines built after S/N 0300071527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
MAIN DISASSEMBLY for “B” Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Assemble Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.4 Re-Aligning Torque Hub Input Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Drive Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.6 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
ii – JLG Lift – 3121180

TABLE OF CONTENTS

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.7 Adjustment Procedure For Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3.8 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
Lockout Cylinder Bleeding (Early Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Lockout Cylinder Bleeding (Ram Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.9 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Check Frame To Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.10 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
One Piece Stator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Two Piece Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
3.11 Semi-Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Normal Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.12 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.13 Ford EFI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96
Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
EFI Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
ECM and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Intake Air Temperature (IAT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Manifold Absolute Pressure (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
ECM Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Throttle Position (TP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3.14 Circuit Testing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-102
Electrostatic Discharge Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
3.15 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-106
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
Cleaning Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.16 Deutz EMR 2 (S/N 85332 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
3.17 GM Engine General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-120
Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3121180 – JLG Lift – iii

TABLE OF CONTENTS

Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Coolant Fill Procedure - Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3.18 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-122
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Electric Lock Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
Low Pressure Regulator (LPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Electronic Throttle Control (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Gasoline Multi Point Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Gasoline Pressure And Temperature Sensor Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Fuel Injector Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3.19 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-126
Propane Fuel System Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Electronic Pressure Regulator (EPR) Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-128
Temperature Manifold Absolute Pressure (TMAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
Electronic Throttle Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
MIXER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Coolant Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Vapor Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3.20 GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132
Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.21 Perkins Engine General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-147
Replacing the Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
Engine Oil and Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
Setting Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.22 Engine Radiator Fill Procedure - Perkins & Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-151
3.23 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS . . . . . . . . . . . . . . . . . . . . . .3-153
Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
Fault Code Broadcast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
MIL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
Diagnostic Calibration Configuration and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . 3-156
Fault/Diagnostic Trouble Code Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
DBW Diagnostic Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
3.24 Diagnostic Trouble Code Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-162
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
iv – JLG Lift – 3121180

TABLE OF CONTENTS

DTC 123- TPS1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-169
DTC 217- ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-171
DTC 219- RPM Higher Than Max Allowed Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . 3-172
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175
DTC 521- Oil Pressure Sender/Switch High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-179
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-183
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-185
DTC 601- Microprocessor Failure - FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-187
DTC 604- Microprocessor Failure - RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191
DTC 642- 5 Volt External Low Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193
DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-194
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-199
DTC 1616- Microprocessor Failure - interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201
DTC 1625- CAN J1939 Shutdown Request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-203
DTC 1626- CAN J1939 Transmit (Tx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-204
DTC 1627- CAN J1939 Receive (Rx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-205
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206
DTC 1629- J1939 TSC1 Message Receipt Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-208
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-209
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-210
DTC 2112- Unable to Reach Higher TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-212
DTC 9999- Throttle Actuator Failsafe Spring Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-214
SECTION 4 - BOOM & PLATFORM
4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Removal of Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly of Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Assembly of Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installation of Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3 Rotary Actuator (S/N 0300130812 and 1300006433 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
SECTION 5 - 3HYDRAULICS
5.1 Cylinder Repair -USA Manufactured Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.2 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Inspect Parts For Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
3121180 – JLG Lift – v

TABLE OF CONTENTS

Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.3 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
Ports and Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Removal and Installation of FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Removal and Installation of FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Charge Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5.4 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .5-40
5.5 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42
Bang-Bang Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Platform Level Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Articulating Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Proportional Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
SECTION 6 - JLG CONTROL SYSTEM
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.3 Using Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.4 Changing Hand Held Analyzer Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.5 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6.6 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6.7 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6.8 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39
Test from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.1 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.3 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
vi – JLG Lift – 3121180

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-3. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-2. Engine Operating Temperature Specifications - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-3. Engine Operating Temperature Specifications - Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-4. Engine Operating Temperature Specifications - GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2-5. Engine Operating Temperature Specifications - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
3-1. Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-2. Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-3. Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5. Housing-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-6. Spindle Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-7. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-8. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-8. Spindle Brake Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3-9. Housing-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-10. Main Assembly Drawing1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-11. Figure 3-11. Main Assembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-12. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-13. Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-14. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-15. Assembly Drawing - With Integral Input Brake - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-16. Assembly Tools - Bearing Cone Pressing - “B” Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-17. Assembly Tools - Bearing Cone Pressing - “A” Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-18. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-19. Assembly Tools - Seal Pressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-20. Assembly Tools - Spacer - Brake Disc Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-21. Assembly Tools - Brake Retaining Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-22. Cluster Gear Punch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-23. Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-24. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-25. Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-26. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
3-28. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-29. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-30. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-31. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-32. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-33. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-34. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
3-35. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
3-36. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
3-37. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-38. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-39. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
3-40. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
3-41. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
3121180 – JLG Lift – vii

LIST OF FIGURES

3-42. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
3-43. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
3-44. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-45. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-47. Chassis Torque Values - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-47. Chassis Torque Values - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-47. Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-48. Swing Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3-49. Swing Bearing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-50. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
3-51. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
3-52. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71
3-53. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71
3-54. Swing Motor - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
3-55. Swing Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74
3-56. Swing Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81
3-57. Track Adjustment and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-91
3-58. Auxiliary Pump - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
3-59. Auxiliary Pump - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-93
3-60. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . .3-95
3-61. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-99
3-62. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103
3-63. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-106
3-64. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
3-65. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-109
3-66. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-110
3-67. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-111
3-68. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
3-69. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-113
3-70. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-114
3-71. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115
3-76. Engine Oil Dip Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-120
3-77. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-122
3-78. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-123
3-79. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-123
3-80. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-124
3-81. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-124
3-82. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125
3-83. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125
3-84. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125
3-85. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-126
3-86. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-127
3-87. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-128
3-88. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-128
3-89. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-129
3-90. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-130
3-91. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132
3-92. GM 3.0L Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-145
3-93. GM 3.0L Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-146
3-94. Crankcase Breather - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-147
3-95. Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-148
3-96. Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-149
viii – JLG Lift – 3121180

LIST OF FIGURES

3-97. Faults Page with Active Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-157
3-98. Faults Page with Historic Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-158
3-99. Custom Fault Variable Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-159
3-100. Historic Fault Information Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-160
3-101. Snapshot Data Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-161
3-102. Flight Data Recorder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-161
3-103. Clear Faults Prompt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-162
3-104. Exhaust Venturi Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-215
3-105. Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-216
4-1. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2. Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-2. Boom Limit Switches - US Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-3. Boom Limit Switches - Euro Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-4. Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-5. Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-6. Rotator Assembly - Cutaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4-7. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-8. Rotary Actuator - Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4-9. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
4-10. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-3. Axle Lockout Cylinder - USA Built Machines Prior to S/N 03000107512 . . . . . . . . . . . . . . . . . . . .5-2
5-4. Axle Lockout Cylinder - Belgium Built Machines Prior to S/N 1300003222 . . . . . . . . . . . . . . . . . .5-3
5-5. Axle Lockout Cylinder - USA Built Machines 0300107512 to Present & Belgium Built Machines
1300003222 to Present5-4
5-6. Platform Level Assembly (450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-7. Platform Level Cylinder (450AJ) - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-8. Platform Level Cylinder (450AJ) - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-9. Jib Cylinder - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-10. Jib Cylinder - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-11. Main Lift Cylinder - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-12. Main Lift Cylinder - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-13. Tower Lift Cylinder - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-14. Tower Lift Cylinder - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-15. Master Cylinder (450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-16. Master Cylinder (450AJ) - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-17. Master Cylinder(450AJ) - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-18. Steer Cylinder - USA Machines Prior to S/N 87393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-19. Steer Cylinder Assembly - USA Machines S/N 87393 to Present . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-20. Steer Cylinder - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5-21. Telescope Cylinder - USA Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-22. Telescope Cylinder - Belgium Built Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
5-23. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5-24. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5-25. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5-26. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5-27. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-28. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-29. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-30. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-31. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-32. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
5-33. Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
5-34. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34
5-35. Plugs/Fittings Size & Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35
5-36. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
3121180 – JLG Lift – ix

LIST OF FIGURES

5-37. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
5-38. Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
5-39. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37
5-40. Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39
5-41. Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43
5-42. Main Control Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44
5-43. Platform Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-2. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-4. ADE Control System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-1. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-14. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-15. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
7-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-18. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7-19. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
7-20. Electrical Schematic - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7-24. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-30. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
x – JLG Lift – 3121180

LIST OF FIGURES

7-36. Electrical Schematic 1001141989 - Sheet 1of 4 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
7-37. Electrical Schematic 1001141989 - Sheet 1of 4 (RH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
7-38. CAT/Perkins Engine Electrical Schematic 1001141989 - Sheet 2 of 4 (LH). . . . . . . . . . . . . . . . . .7-30
7-39. CAT/Perkins Engine Electrical Schematic 1001141989 - Sheet 2 of 4 (RH) . . . . . . . . . . . . . . . . .7-31
7-40. Deutz Engine Electrical Schematic 1001141989 - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
7-41. GM/PSI Engine Electrical Schematic 1001141989 - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .7-33
7-42. Electrical Schematic 1001102901(LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34
7-43. GM/PSI Engine Electrical Schematic 1001102901 (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
7-44. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36
7-45. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
7-50. Hydraulic Schematic 1283460 - Sheet 1 of 7 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42
7-50. Hydraulic Schematic 1283460 - Sheet 1 of 7 (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42
7-58. Hydraulic Schematic 1283460 - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
7-59. Hydraulic Schematic 1283460 - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
3121180 – JLG Lift – xi

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Deutz F3M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Deutz F3M2011F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-6 Caterpillar 3024/C2.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Reach Specifications - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-10 Dimensional Data - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-11 Chassis Specifications - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-12 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-13 Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-14 Engine Torque Requirements - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Engine Torque Requirements - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-16 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-17 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-18 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-19 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-20 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-21 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-22 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-23 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-24 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-25 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Motor Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-3 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-4 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-5 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-6 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-7 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
3-8 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
3-9 Chassis Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-10 Chassis Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-11 Swing Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
3-12 Adjustment Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
3-13 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97
3-14 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-133
3-15 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-135
3-16 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-143
3-17 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-155
3-18 Diagnostic Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-156
3-19 Historic Fault Information Interface Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-160
5-1 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
5-3 Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31
5-4 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-2 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . .6-22
6-3 Machine Configuration Programming Information Software Version P5.3 to P6.1 . . . . . . . . . . . .6-26
6-4 Machine Configuration Programming Information Software Version P6.1 to Present. . . . . . . . . .6-31
6-5 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
6-6 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
6-7 Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949 . . . . . . . . . . . . . . . .6-56
6-8 Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present . . . 6-59
xii – JLG Lift – 3121180

SECTION 1. SPECIFICATIONS
1.1 CAPACITIES Table 1-4. Deutz F3M1011F
Fuel Diesel
Table 1-1. Capacities
No. of Cylinders 3s
Fuel Tank 17 gallons (64.3 liters) Bore 3.6 in. (91 mm)
Hydraulic Tank Stroke 4.4 in. (112 mm)
(machines to S/N 0300070586) 28 gallons (106 liters)
Displacement 133 cu. in. (2184 cm³)
Hydraulic Tank 27 gallons (102 liters)
BHP at Max. RPM 48
(S/N 0300070586 & 23.6 gal. (89 liters) to the Full line
SN 1300000001to Present) on the sight gauge Oil Capacity
crankcase 6.3 quarts (6 L)
Drive Hub 23.75 oz. (0.7 liters)
cooler 4.75 quarts (4.5 L)
Drive Brake 2.7 oz. (0.08 liters) total capacity 11 quarts (10.5 L)
Low RPM 1200
1.2 TIRES Mid RPM
Tower Lift, Upper Lift, Tele
Table 1-2. Tires Swing, Basket Level, Basket 1800
Rotate, Jib Lift 1500
Size Type Pressure Weight High RPM 2800
12x16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg)
12x16.5 Foam-Filled N/A 328 lbs. (149 kg) Table 1-5. Deutz F3M2011F
33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lbs. (61 kg)
Fuel Diesel
33/1550x16.5 Foam-Filled N/A 395 lbs. (179 kg)
No. of Cylinders 3s
14 x 16.1 Pneumatic 40 lbs. (3 bar) 91.5 lbs. (41.5 kg)
Bore 3.7 in. (94 mm)
14 x 16.1 Foam-Filled N/A 426 lbs. (193 kg)
Stroke 4.4 in. (112 mm)
Displacement 142 cu. in. (2331 cm³)
1.3 ENGINE Oil Capacity
crankcase 6.3 quarts (6 L)
NOTE: RPM Tolerances are ± 100. cooler 4.75 quarts (4.5 L)
total capacity 11 quarts (10.5 L)
Table 1-3. Ford LRG-425 (Gas or Dual Fuel) Low RPM 1200
Mid RPM
Type 4 cylinder, 4 stroke, spark ignition Tower Lift, Upper Lift, Tele
Fuel Gasoline or Gasoline/LP Gas Swing, Basket Level, Basket 1800
Bore 3 in. (96 mm) Rotate, Jib Lift 1500
Stroke 3.4 in. (86.4 mm) High RPM 2800
Displacement 153 cu. in. (2.5 L)
Firing Order 1-3-4-2
BHP at Max. RPM 82
Oil Capacity 4.5 quarts (4.26 L)
Low RPM 1000
Mid RPM
Tower Lift, Upper Lift, Tele 1800
Swing, Basket Level, Basket 1500
Rotate, Jib Lift
High RPM 3000
Spark Plug AWSF-52-C
Spark Plug Gap 0.044 in. (1.117 mm)
3121259 – JLG Lift – 1-1

Table 1-6. Caterpillar 3024/C2.2 1.4 SPECIFICATIONS AND PERFORMANCE

Fuel Diesel DATA
No. of Cylinders 4
Reach Specifications
BHP 46.5 hp (34 kW)
Bore 3.307 in. (84 mm) Table 1-9. Reach Specifications - 450
Stroke 3.9370 in. (112 mm)
Max. Platform Height 45ft. (13.72 M)
Displacement 134.3 cu. in. (2.2L)
Max. Horizontal Reach 24.5ft. (7.47 M)
Oil Capacity 10 qt. (9.4 L)
Up & Over Height 25 ft. 2 in. (7.7 M)
Compression Ratio 19:1
Main Boom Up Angle 75°
Main Boom Down Angle -24°
Max. RPM 2800
Dimensional Data
Table 1-7. GM 3.0L
Table 1-10. Dimensional Data - 450
Fuel Gasoline or Gasoline/LP Gas
No. of Cylinders 4 Overall Width
(12 x 16.5 tire) 6 ft. 6 in. (1.98 m)
BHP
(33/1550 tire) 6 ft. 10 in. (2.08 m)
Gasoline 83 hp @ 3000 rpm
(14 x 16.1 tire) 6 ft. 11 in. (2.11 m)
LP 75 hp @ 3000 rpm
Tailswing 0
Bore 4.0 in. (101.6 mm)
Stowed Height 7 ft. 4.4 in. (2.25 m)
Stroke 3.6 in. (91.44 mm)
Stowed Length 21 ft. 4 in. (6.5 m)
Displacement 181 cu.in. (3.0 L, 2966 cc)
Wheel base 78 in. (1.98 m)
Oil Capacity w/filter 4.5 qts. (4.25 L)
Track Width
Minimum Oil Pressure
(12 x 16.5 tire) 65.3 in. (1.66 m)
at idle 6 psi (0.4 Bar) @ 1000 rpm
(33/1550 tire) 66.3 in. (1.69 m)
Hot 18 psi (1.2 Bar) @ 2000 rpm
(14 x 16.1 tire) 66.6 in. (1.69 m)
Compression Ratio 9.2:1
Ground Clearance 14 in. (0.36 m)
Max. RPM 2800
Chassis
Table 1-8. Perkins 404C-22 Table 1-11. Chassis Specifications - 450
Fuel Diesel Swing 357° non-continuous

No. of Cylinders 4 Rated Gradeability
BHP 50 HP (37.3 kW) 2WD 30%
4WD 45%
Bore 3.3 in. (84 mm)
Max. Tire Load 7900 lb. (3583 kg)
Stroke 3.9 in. (100 mm)
Axle Oscillation 8 in. (0.2 m)
System Voltage 12 Volts
Displacement 135 cu.in. (2.2 L)
Max. Hydraulic System Operating 4500 psi
Oil Capacity w/filter 10 qt. (9.4 L) Pressure (310 bar)
Compression Ratio 23.3:1 Gross Machine Weight
Fuel Consumption 0.63 gal. (2.38 L) /hour 450A SII 14,500 lbs. (6577 kg)
450AJ SII 16,500 lbs. (7484 kg)
1-2 – JLG Lift – 3121259

1.5 FUNCTION SPEEDS Platform Rotate: Platform level and completely rotated
one direction. Rotate opposite direction, record time.
Table 1-12. Function Speeds (In Seconds) Rotate other direction, record time.
Articulating Jib: Platform level and centered with boom.
Function 450A 450AJ
Start with Jib down. Jib up, record time. Jib down, record
Main Lift Up 24-28 24-28 time.
Main Lift Down 20-24 20-24
Lower Lift: Upper Boom horizontal. Telescoped In. Lower
Swing Right & Left* 70-90 70-90 Lift up, record time. Lower lift down, record time.
Telescope Out 18-22 16-20
Telescope In 12-16 9-14 Test Notes
Platform Rotate Right & Left** 25-32 25-32 1. Start stop watch with function, not with controller or
Jib Up N/A 21-31 switch.
Jib Down N/A 19-25 2. Drive test results reflect 12x16.5 tires.
Lower Lift Up 30-38 30-38 3. All speed tests are run from platform. These speeds
Lower Lift Down 22-28 22-28 do not reflect ground control operation.
Drive (2WD High Engine) 38-41 38-41 4. Platform speed knob control must be at full speed
(3.5 MPH) (3.5 MPH) (turned clockwise completely).
Drive (4WD High Engine) 29-31 29-31
(4.5 MPH) (4.5 MPH) 5. Test with oil temperature above 100° F (38° C). Func-
tion speeds vary if hydraulic oil is cold and thick.
Drive above Horizontal 46-68 46-68
(50 ft.) (0.75 - 0.50 (0.75 - 0.50 6. Some flow control functions may not work with
MPH) MPH) speed knob clicked into creep position.
*Max 10% Difference Between Left & Right
**Max 15% Difference Between Left & Right 1.6 TORQUE REQUIREMENTS
Table 1-13. Torque Specification
Machine Orientation When Doing Speed Description Torque Value Interval Hours
Tests Wheel Lugs 170 ft. lb. 150
(230 Nm)
Lift: Boom retracted. Telescope retracted. Lift up, record
Semi-Track 90 ft. lb. 150
time, Lift down, record time. Wheel Lugs (122 Nm)
Swing Bearing 190 ft. lb. 50/600*
Swing: Boom at full elevation. Telescope retracted. Swing (Loctite) (257 Nm)
turntable to end stop. Swing opposite direction, record
Starter Solenoid
time. Swing opposite direction, record time. Contacts 95 in. lbs. (9.5 Nm) As required
Coil 40 in. lbs. (4 Nm)
Telescope: Boom at full elevation; Telescope retracted;
Drive Hub to Axle 240 ft. lb. As required
Telescope out, record time. Telescope In, record time.
(325 Nm)
Drive: Test to be done on a smooth level surface. Set Drive Motor to Axle 120 ft. lb. As required
Drive Select Switch to 2WD High Engine. Start approxi- (163 Nm)
mately 25 ft (7.62 m) from starting point so unit is at maxi- *Check swing bearing bolts for security after first 50 hours of operation
mum speed when starting test. Record results for a 200 ft. and every 600 hours thereafter.
(60.96 m) course. Drive forward, record time. Drive
reverse, record time.
Drive (Above Horizontal): Test should be done on a

smooth level surface. Set Drive Select Switch to 2WD High
Engine. Select Platform Speed Knob out of creep speed.
This verifies switches are working when boom is above
horizontal. Results should be recorded for a 50 ft course.
Drive forward, record time. Drive reverse, record time.
3121259 – JLG Lift – 1-3

Table 1-14. Engine Torque Requirements - Ford Table 1-15. Engine Torque Requirements - Deutz
Torque Value Torque Value Torque Value Torque Value

Description Description
ft. lb. Nm ft. lb. Nm
Oil Drain Plug 15-25 20-34 Cylinder Head Cover 6 8.5
Spark Plugs 7-15 9-20 Cylinder Head Cover 6 8.5
Pump Coupling (dry) 26.5 37 Rocker Arm Adjustment 15 21

Screw
Pump Coupling (Loctite 28.5 40
#242) Intake Manifold 6 8.5
Flywheel 54-64 73-87 Air Intake Pipe 15 21

Mechanical Governor Belt 70 311.4 Exhaust Manifold 28.5 40
Tension (New) (F3M1011)
Mechanical Governor Belt 50 222.4 Exhaust Manifold 16 22

Tension (Used)* (F3M2011)
* A used belt is one that has been in operation for 10 minutes or more. Oil Drain Plug 39 55
Oil Pan (sheet metal) 15 21
Oil Pan (cast) 22 31
Pump Coupling (dry) 26.5 37
Pump Coupling (Loctite 28.5 40

#242)
Injection Line Attachment 16 22

(F3M1011)
Injection Line Attachment 21 30

(F3M2011)
Injection Valve Attachment 15 21
Lube Oil Filter Cartridge 19 27
1-4 – JLG Lift – 3121259

1.7 LUBRICATION
Table 1-18. Mobil DTE 13M Specs
Hydraulic Oil ISO Viscosity Grade #32
Specific Gravity 0.877
Table 1-16. Hydraulic Oil
Pour Point, Max -40°F (-40°C)
Hydraulic System Flash Point, Min. 330°F (166°C)
S.A.E. Viscosity
Operating
Grade Viscosity
Temperature Range
at 40° C 33cSt
+0° to + 180° F 10W
(-18° to +83° C) at 100° C 6.6 cSt
+0° to + 210° F 10W-20, 10W30 at 100° F 169 SUS
(-18° to +99° C) at 210° F 48 SUS
+50° to + 210° F 20W-20 cp at -20° F 6,200
(+10° to +99° C Viscosity Index 140
NOTE: Hydraulic oils must have anti-wear qualities at least to

API Service Classification GL-3, and sufficient chemi- Table 1-19. UCon Hydrolube HP-5046
cal stability for mobile hydraulic system service. JLG
Type Synthetic Biodegradable
Industries recommends Mobilfluid 424 hydraulic oil,
which has an SAE viscosity index of 152. Specific Gravity 1.082
NOTE: When temperatures remain consistently below 20°F (-7°C),
pH 9.1
JLG Industries recommends using Mobil DTE13.
Viscosity
Aside from JLG recommendations, it is not advisable to mix at 0° C (32° F) 340 cSt (1600SUS)
oils of different brands or types, as they may not contain the at 40° C (104° F) 46 cSt (215SUS)
same required additives or be of comparable viscosities. If
at 65° C (150° F) 22 cSt (106SUS)
use of hydraulic oil other than Mobilfluid 424 is desired,
contact JLG Industries for proper recommendations. Viscosity Index 170
Table 1-17. Mobilfluid 424 Specs
SAE Grade 10W30 Table 1-20. Mobil EAL H 46 Specs

Gravity, API 29.0
Type Synthetic Biodegradable
Density, Lb/Gal. 60°F 7.35
ISO Viscosity Grade 46
Specific Gravity .910
Flash Point, Min. 442°F (228°C)
Pour Point -44°F (-42°C)
Viscosity
Flash Point 500°F (260°C)
Brookfield, cP at -18°C 2700
Operating Temp. 0 to 180°F (-17 to 162°C)
at 40° C 55 cSt
Weight 7.64 lb. per gal.
at 100° C 9.3 cSt (0.9 kg per liter)
Viscosity Index 152 Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121259 – JLG Lift – 1-5

1.9 PRESSURE SETTINGS - PSI (BAR)

Table 1-21. Exxon Univis HVI 26 Specs
Specific Gravity 32.1 Table 1-24. Pressure Settings

Pour Point -76°F (-60°C) SETTING PSI BAR
Flash Point 217°F (103°C) Bang-Bang Main Relief 3300 227.5
Viscosity Steer 2500 172
at 40° C 25.8 cSt Platform Level Up 2800 193
at 100° C 9.3 cSt Platform Level Down 1800 124
Viscosity Index 376 Platform Rotate 1800 124
NOTE: Mobil/Exxon recommends that this oil be Articulating Jib 1500 103
checked on a yearly basis for viscosity.
Proportional Main Relief 3200 220
Lift Down 1200 83
Table 1-22. Quintolubric 888-46
Swing 1700 117
Density 0.91 @ 15°C (59°F)
Pour Point <-20°C (<-4°F) 1.10 SERIAL NUMBER LOCATION
Flash Point 275°C (527°F) A serial number plate is attached to left rear side of frame.
Fire Point 325°C (617°F) If serial number plate is damaged or missing, machine
serial number is also stamped on left side of frame.
Autoignition Temperature 450°C (842°F)
Viscosity
at 0° C (32°F) 360 cSt
at 20° C (68°F) 102 cSt
at 40° C (104°F) 46 cSt
at 100° C (212°F) 10 cSt
Viscosity Index 220
1.8 MAJOR COMPONENT WEIGHTS

Table 1-23. Component Weights
Component Pounds Kilograms

Frame 2325 1055
Turntable 1500 680
Boom Link 180 82
Boom Timing Link 30 14
Upper Upright 217 98 Figure 1-1. Serial Number Locations
Lower Upright 115 52
Lower Boom 497 225
Mid Boom 385 175
Upper Boom 1065 484
4 Wheel Drive Axle 200 91
2 Wheel Drive Axle 235 107
1-6 – JLG Lift – 3121259

4
7,8 1
3 4 5 2A
3 4 2B 4
9,10,11,12,13,14,15
16,17,18,19,20,21
Figure 1-2. Operator Maintenance and Lubrication Diagram
1.11 OPERATOR MAINTENANCE 1. Swing Bearing - Internal Ball Bearing

Lube Point(s) - 2 Grease Fittings
NOTE: The following numbers correspond to those in Figure Capacity - A/R
1-2., Operator Maintenance and Lubrication Diagram. Lube - MPG
Interval - Every 3 months or 150 hrs of operation.
Table 1-25. Lubrication Specifications 2. A. Swing Bearing - Teeth
KEY SPECIFICATIONS Lube Point(s) - Spray On
MPG Multipurpose Grease having a minimum dripping point of Capacity - A/R
350° F (177° C). Excellent water resistance and adhesive Lube - OGL
qualities, and being of extreme pressure type. Interval - Every 3 months or 150 hrs of operation.
(Timken OK 40 pounds minimum.)
B. End Bearings - Worm Gear*
EPGL Extreme Pressure Gear Lube (oil) meeting API service classi-
fication GL-5 or MIL-Spec MIL-L-2105 Lube Point(s) - 2 Grease Fittings
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424. Capacity - A/R
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L- Lube - MPG
2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C. Interval - Every 2 years or 1200 hrs of operation.
Comments - Remove grease fittings and install
OGL Open Gear Lubricant - Mobiltac 375 or equivalent. plugs after greasing.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION

UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-
SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON-
MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
NOTE: It is recommended as a good practice to replace all *Install grease fittings into worm gear housing and
filters at the same time. grease bearings if necessary.
3121259 – JLG Lift – 1-7

6. Hydraulic Charge Filter
DO NOT OVERGREASE END BEARINGS OR HOUSING OUTER SEAL

MAY BLOW AND CAUSE DAMAGE TO EQUIPMENT.
3. Wheel Bearings (2WD Only)
Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter or as indicated by
Condition Indicator.
Lube Point(s) - Repack
7. Hydraulic Tank
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation.
4. Wheel Drive Hub
Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation.
5. Hydraulic Return Filter
Lube Point(s) - Fill Cap

Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters)
to the Full line on the sight gauge.
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
Interval - Change after first 50 hrs., every six months,
or 300 hrs. thereafter, or as required by Condition
Indicator.
1-8 – JLG Lift – 3121259

8. Suction Strainers 10. Oil Change w/Filter - Deutz
Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts
(4.7 L) Cooler
Lube - EO
Lube Point(s) - 2 Interval - Every Year or 1200 hours of operation.
Interval - Every 2 years or 1200 hours of operation, Comments - Check level daily/Change in accor-
remove and clean at time of hydraulic oil change. dance with engine manual.
9. Oil Change w/Filter - Ford 11. Oil Change w/Filter - Caterpillar

Capacity - 10 Quarts (9.4 L)
Lube - EO
Interval - Every Year or 600 hours of operation.
Comments - Check level daily/Change in accor-
dance with engine manual.
12. Oil Change w/Filter - GM

Capacity - 4.5 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation.
Comments - Check level daily/Change in accordance
with engine manual.

(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation.
3121259 – JLG Lift – 1-9

13. Oil Change w/Filter - Perkins 17. Fuel Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N
7026855)
Capacity - 10 Quarts (9.4 L)
Lube - EO
14. Fuel Filter - Ford
Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation.
18. Fuel Filter - Perkins

19. Air Filter

Interval - Every Year or 1200 hours of operation
15. Fuel Filter - Deutz

Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator.
20. Electronic Pressure Regulator (LP only)

16. Fuel Filter - Caterpillar
Interval - 3 Months or 150 hours of operation

Comments - Drain oil build up. Refer to Draining Oil
Build Up From The Propane Regulator.
1-10 – JLG Lift – 3121259

21. Fuel Filter (Propane) - GM Engine 4. Push Emergency Stop when engine stops.
Interval - 3 Months or 150 hours of operation

Comments - Replace filter. Refer to Propane Fuel Filter
Replacement.
5. Disconnect electrical connection to LPG fuel tem-
1.12 DRAINING PROPANE REGULATOR OIL perature sensor in auxiliary fuel port of the EPR.
BUILD UP (PRIOR TO S/N 0300137808)
6. Remove LPG fuel temperature sensor retainer clip
Operation oils may build in propane pressure regulator and sensor from regulator body.
primary and secondary chambers during normal use.
These oils are caused by poor fuel quality, fuel supply
chain contamination, or regional variation in fuel make
up. Significant oil buildup can effect fuel control system
operation. Refer to Section 1.11, Operator Mainte-
nance for maintenance intervals. More frequent drain-
ing may be required if fuel supply is contaminated.
NOTE: Warm engine to operating temperature before drain-

ing For best results. this will allow oils to flow freely
from regulator.
1. Move equipment to a well ventilated area. Ensure

there are no external ignition sources.
2. Start engine and bring to operating temperature.
3. With engine running, close manual tank valve and NOTE: Have a small container ready to collect oil that drains
run engine out of fuel. freely from regulator.
7. Drain all oil. Reinstall LPG fuel temperature sensor

and reconnect electrical connector.
8. Open fuel tank manual valve.
9. Pull out Emergency Stop and start engine. Verify all
connections are secure.
10. Dispose of any drained oil per local regulations in a
safe and proper fashion.
3121259 – JLG Lift – 1-11

1.13 PROPANE FUEL FILTER REPLACEMENT 3. Pull filter housing from electric lock off assembly.
4. Remove filter from housing.
Removal 5. Locate filter magnet and remove it.
1. Relieve propane fuel system pressure. Refer to 1.14 6. Remove and discard housing seal.
Propane Fuel System Pressure Relief. 7. If equipped, remove and discard retaining bolt seal.
2. Disconnect negative battery cable. Slowly loosen 8. Remove and discard mounting plate to lock off O-ring
and remove filter housing. seal.
1 7 1 7
8 8
2 13
9 9
3 3
10 10
4 OR 4
5 5
11
6
11
12
1. Electric Lock Off Solenoid 6. Seal 10. Filter

2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet
3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt
4. Filter Magnet 9. O-Ring 13. Ring
5. Filter Housing
Figure 1-3. Filter Lock Assembly
Installation 1.14 PROPANE SYSTEM PRESSURE RELIEF

NOTE: NOTE: Reinstall filter magnet in housing before
installing new seal.
PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI
1. Install mounting plate to lock off O-ring seal. (21.5 BAR). RELIEVE PROPANE FUEL SYSTEM PRESSURE (WHERE
2. If equipped, install retaining bolt seal. APPLICABLE) BEFORE SERVICING PROPANE FUEL SYSTEM COM-
PONENTS TO MINIMIZE RISK OF FIRE AND PERSONAL INJURY.
3. Install housing seal.
4. Drop magnet into bottom of filter housing. 1. Close manual shut-off valve on propane fuel tank.
5. Install filter into housing. 2. Start and run vehicle until engine stalls.
6. If equipped, install retaining bolt in filter housing.
3. Turn ignition switch OFF.
7. Install filter to bottom electric lock off.
8. Tighten filter bowl retainer to 106 in-lb (12 Nm).
9. Open manual shut-off valve. Start vehicle and leak RESIDUAL VAPOR PRESSURE IS PRESENT IN FUEL SYSTEM. ENSURE
check propane fuel system at each serviced fitting. WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY
Refer to Propane Fuel System Leak Test. FUEL LINE.
1-12 – JLG Lift – 3121259

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description
0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red)
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7)
3121259 – JLG Lift – 1-13

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
3. * ASSEMBLY USES HARDENED WASHER
1-14 – JLG Lift – 3121259

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM
Tensile Clamp Load Torque
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
3121259 – JLG Lift – 1-15

SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
1-16 – JLG Lift – 3121259

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS
Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITE TM 111 or
140)
Sq mm KN [N.m] [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NO. 5000059 REV. J
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7)
3121259 – JLG Lift – 1-17

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
1-18 – JLG Lift – 3121259

Magni Coating (Ref 4150701)*
CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*
Torque
Torque
Torque (Lub OR Loctite®
Tensile (Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
Size PITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16
Sq mm kN [N.m] [N.m] [N.m]
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
3121259 – JLG Lift – 1-19

NOTES:
1-20 – JLG Lift – 3121259

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form, and Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection.
Reference appropriate areas of this manual for servicing
General and maintenance procedures.
This section provides information needed to place Annual Machine Inspection

machine in operation readiness and maintain its safe
operating condition. Ensure all inspections and mainte- The Annual Machine Inspection must be performed no
nance have been completed before placing machine into later than 13 months from date of prior Annual Machine
service for safe operation and maximum service life. Inspection. It is recommended the annual inspection be
done by a JLG Factory-Certified Service Technician.
Preparation, Inspection, and Maintenance Reference JLG Annual Machine Inspection Form and
Inspection and Preventative Maintenance Schedule for
It is important to establish a comprehensive inspection items requiring inspection. Refer to appropriate areas of
and preventive maintenance program. Table 2-1 outlines this manual for service and maintenance procedures.
periodic machine inspections and maintenance recom-
For purpose of receiving safety-related bulletins, it is
mended by JLG Industries, Inc. Consult your national,
important that JLG Industries, Inc. has updated ownership
regional, or local regulations for further requirements for information for each machine. When performing each
aerial work platforms. Increase frequency of inspections Annual Machine Inspection, notify JLG Industries, Inc. of
and maintenance as environment, severity, and frequency any change in machine ownership.
of usage requires.
Preventative Maintenance
Pre-Start Inspection
In conjunction with specified inspections, maintenance
shall be performed by a qualified JLG equipment
It is the User’s or Operator’s primary responsibility to per-
mechanic. JLG Industries, Inc. recognizes a qualified JLG
form a Pre-Start Inspection of the machine prior to use
equipment mechanic as a person who, by possession of a
daily or at each change of operator. Follow the Operator’s
recognized degree, certificate, extensive knowledge, train-
and Safety Manual Pre-Start Inspection procedures. The
ing, or experience, has successfully demonstrated ability
Operator and Safety Manual must be read in its entirety
and proficiency to service, repair, and maintain the subject
and understood before performing a Pre-Start Inspection.
JLG product model.
Pre-Delivery Inspection and Frequent Reference Preventative Maintenance Schedule and

appropriate areas of this manual for servicing and mainte-
Inspection nance procedures. Frequency of service and mainte-
nance must be increased as environment, severity, and
The Pre-Delivery Inspection and Frequent Inspection shall frequency of usage requires.
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recog-
nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
Pre-Delivery Inspection and Frequent Inspection procedures

are performed in the same manner, but at different times.
The Pre-Delivery Inspection shall be performed prior to each
sale, lease, or rental delivery. The Frequent Inspection shall
be accomplished for each machine in service for 3 months
or 150 hours (whichever comes first); out of service for more
than 3 months; or when purchased used. Frequency of this
inspection must be increased as environment, severity, and
frequency of usage requires.
3121180 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
Inspection rental delivery. Mechanic Manual and applicable JLG
inspection form.
Frequent Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance
ever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
Purchased used.
Annual Machine Annually, no later than 13 months from the Owner, Dealer, or User Factory-Certified Service and Maintenance
Inspection date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clean openings, fittings, and adjacent areas.
As soon as a line or component is disconnected,
General cap or cover all openings to prevent entry of foreign
The following information is provided to assist you in the matter.
use and application of servicing and maintenance proce-
3. Clean and inspect all parts during servicing or main-
dures contained in this manual.
tenance. Ensure all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed.
Keep new parts in their containers until needed.
Your safety, and that of others, is the first consideration
during maintenance of equipment. Always be conscious
of weight. Never attempt to move heavy parts without the
Components Removal and Installation
aid of a mechanical device. Do not allow heavy objects to 1. Use adjustable lifting devices if mechanical assis-
rest in an unstable position. When raising a portion of the tance is required. All slings (chains, cables, etc.)
equipment, ensure that adequate support is provided. should be parallel to each other and as near perpen-
dicular as possible to top of part being lifted.
Cleanliness 2. Should it be necessary to remove a component on
1. The most important single item in preserving the an angle, keep in mind the capacity of an eyebolt or
long service life of a machine is to keep dirt and for- similar bracket lessens, as the angle between the
eign materials out of the vital components. Precau- supporting structure and component becomes less
tions have been taken to safeguard against this. than 90 degrees.
Shields, covers, seals, and filters are provided to 3. If a part resists removal, check to see whether all
keep air, fuel, and oil supplies clean; however, these nuts, bolts, cables, brackets, wiring, etc., have been
items must be maintained on a scheduled basis in removed and no adjacent parts are interfering.
order to function properly.
2-2 – JLG Lift – 3121180

SECTION 2 - GENERAL
Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring

Complete steps in sequence when disassembling or reas- Clearly mark or tag hydraulic lines, electrical wiring, and
sembling a component. Do not partially disassemble or their receptacles when disconnecting or removing them.
assemble one part, then start on another. Always recheck This ensures they will be correctly reinstalled.
your work to ensure nothing has been overlooked. Do not
make any adjustments, other than those recommended, Hydraulic System
without obtaining proper approval.
1. Keep system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain
Pressure-Fit Parts and flush entire system.
2. Disassemble and reassemble parts on clean work
Use anti-seize or a molybdenum disulfide base com-
surface. Clean all metal parts with non-flammable
pound to lubricate the mating surface when assembling
cleaning solvent. Lubricate components to aid
pressure-fit parts.
assembly if required.
Bearings Lubrication
Service applicable components with amount, type, and
1. When a bearing is removed, cover it to keep out dirt
grade of lubricant recommended in this manual, at speci-
and abrasives. Clean bearings in nonflammable
fied intervals. When recommended lubricants are not
cleaning solvent and allow to air dry. Compressed
available, consult your local supplier for an equivalent that
air can be used, but do not spin bearing.
meets or exceeds specifications.
2. Discard bearings if races and balls (or rollers) are
pitted, scored, or burned. Battery
Clean battery with a non-metallic brush and a solution of
3. If bearing is serviceable, apply a light coat of oil and
baking soda and water. Rinse with clean water. After
wrap it in clean (waxed) paper. Do not unwrap reus-
cleaning, thoroughly dry battery and coat terminals with
able or new bearings until ready to install.
an anti corrosion compound.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
Lubrication and Servicing
or bore, apply pressure to the outer race. If bearing Components and assemblies requiring lubrication and
is to be installed on a shaft, apply pressure to the servicing are shown in the Lubrication Chart in Section 1.
inner race.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications as the original or equivalent.
2. Unless specific torque requirements are given within

the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accor-
dance with recommended shop practices. (See
Torque Chart Section 1.)
3121180 – JLG Lift – 2-3

SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION

SYSTEMS USING DTE 13 OIL SHOULD NOT BE OPERATED AT
Hydraulic System TEMPERATURES ABOVE 200 DEGREES F (94 DEGREES C) UNDER
ANY CONDITION.
1. Contamination is the primary enemy of a hydraulic
system. Contaminants enter the system by using 4. The only exception to the previous is to drain and fill
inadequate hydraulic oil, allowing moisture, grease, the system with Mobil DTE 13 oil or equivalent. This
filings, sealing components, sand, etc., to enter allows start up at temperatures down to -20° F (-29°C).
when performing maintenance, or by allowing the However, use of this oil will give poor performance at
pump to cavitate due to insufficient system warm- temperatures above 120°F (49° C).
up, or leaks in the pump supply (suction) lines.
Changing Hydraulic Oil
2. Design and manufacturing tolerances of component
working parts are very close. Even the smallest 1. Use of any recommended crankcase or hydraulic
amount of dirt or foreign matter entering a system oils eliminates the need for changing oil on a regular
can cause wear or damage to components and ca basis. However, filter elements must be changed
after the first 50 hours of operation and every 300
cause faulty operation. Take every precaution to
hours thereafter. If it is necessary to change the oil,
keep hydraulic oil clean, including reserve oil in stor-
use only those oils meeting or exceeding specifica-
age. Hydraulic system filters should be checked,
tions appearing in this manual. If unable to obtain
cleaned, and/or replaced as necessary, at intervals
the same type of oil supplied with the machine, con-
specified in the Lubrication Chart in Section 1.
sult local supplier for assistance in selecting the
Always examine filters for evidence of metal parti-
proper equivalent. Avoid mixing petroleum and syn-
cles.
thetic base oils. JLG Industries recommends chang-
ing the hydraulic oil annually.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or cor- 2. Use every precaution to keep hydraulic oil clean. If
rosion. If this condition occurs, the system must be oil must be poured from original container into
drained, flushed, and refilled with clean oil. another, clean all possible contaminants from the
service container. Always clean filter mesh element
4. It is not advisable to mix oils of different brands or and replace cartridge any time system oil is
types, as they may not contain the same required changed.
additives or be of comparable viscosities. Good
3. While unit is shut down, make a thorough inspection
grade mineral oils, with viscosities suited to ambient
of all hydraulic components, lines, fittings, etc., as
temperatures in which the machine is operating, are
well as a functional check of each system, before
recommended for use.
placing machine back in service.
NOTE: Metal particles may appear in oil or filters of new
machines due to wear-in of meshing components.
Lubrication Specifications
Specified lubricants, as recommended by the component
manufacturers, are always the best choice. However,
Hydraulic Oil multi-purpose greases usually have qualities which meet a
variety of single purpose grease requirements. Should
1. Refer to Section 1 for recommendations for viscosity any question arise regarding use of greases in mainte-
ranges. nance stock, consult your local supplier for evaluation.
Refer to Section 1 for an explanation of the lubricant key
2. JLG recommends Mobilfluid 424 hydraulic oil, which
designations appearing in the Lubrication Chart.
has an SAE viscosity of 10W-30 and a viscosity
index of 152.
STARTUP OF HYDRAULIC SYSTEM WITH OIL TEMPERATURES

BELOW -15°F (-26°C) IS NOT RECOMMENDED.
3. If it is necessary to start the system in a sub-zero

environment, heat oil with a low density, 100VAC
heater to a minimum temperature of -15°F (-26°C).
2-4 – JLG Lift – 3121180

SECTION 2 - GENERAL
2.4 CYLINDER DRIFT TEST 2.5 PINS AND COMPOSITE BEARING

Measure maximum acceptable cylinder drift using the fol- REPAIR GUIDELINES
lowing methods.
Filament wound bearings.
Platform Drift 1. Pinned joints should be disassembled and

inspected if the following occurs:
Measure platform to ground drift. Lower booms (if
equipped) slightly elevated, upper boom fully extended a. Excessive sloppiness in joints.
with rated load in the platform and power off. Maximum b. Noise originating from joint during operation.
allowable drift is 2" (5 cm) in 10 minutes. If machine does
2. Filament wound bearings should be replaced if any
not pass this test, proceed with the following:
of the following is observed:
Cylinder Drift a. Frayed or separated fibers on liner surface.

b. Cracked or damaged liner backing.
Table 2-2. Cylinder Drift c. Bearings that have moved or spun in their housing.
Max. Acceptable Drift d. Debris embedded in liner surface.
Cylinder Bore Diameter
in 10 Minutes 3. Pins should be replaced if any of the following is
inches mm inches mm observed (pin should be properly cleaned prior to
inspection):
3 76.2 0.026 0.66
3.5 89 0.019 0.48 a. Detectable wear in bearing area.
4 101.6 0.015 0.38 b. Flaking, pealing, scoring, or scratches on pin
surface.
5 127 0.009 0.22
c. Rusting of pin in bearing area.
6 152.4 0.006 0.15
7 177.8 0.005 0.13 4. Re-assembly of pinned joints using filament wound
bearings.
Drift is to be measured at cylinder rod with a calibrated a. Housing should be blown out to remove all dirt
dial indicator. Cylinder oil must be at ambient temperature and debris. Bearings and bearing housings
and temperature stabilized. must be free of all contamination.
b. Clean bearing/pins with a solvent to remove all
Cylinder must have normal platform load applied.
grease and oil. Filament wound bearing are a
dry joint and should not be lubricated.
If cylinder passes this test, it is acceptable.
c. Inspect pin to ensure it is free of burrs, nicks,
NOTE: This information based on 6 drops per minute cylinder and scratches which would damage bearing
leakage. during installation and operation.
3121180 – JLG Lift – 2-5

SECTION 2 - GENERAL
2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to
the machine and to welding performed from machine
on an external structure, or component,
DO the Following When Welding on JLG

Equipment
• Disconnect battery.
• Disconnect moment pin connection (where fitted).
• Ground only to structure being welded.
DO NOT Do the Following When Welding on

JLG Equipment
• Ground on frame and weld on any other area than
chassis.
• Ground on turntable and weld on any other area than
turntable.
• Ground on platform/support and weld on any other
area than platform/support.
• Ground on a specific boom section and weld on any
other area than that specific boom section.
• Allow pins, wear pads, wire ropes, bearings, gearing,
seals, valves, electrical wiring, or hoses to be between
grounding position and welded area.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY

RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
2-6 – JLG Lift – 3121180

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Weekly Monthly Pre-Delivery2 Annual4

Pre-Start1 Preventive Preventive or Frequent3
Every 2
(Yearly) Years
Inspection Maintenance Maintenance Inspection Inspection
Boom Assembly 9
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Gate 5 1 1,5
Floor 1,2 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 2 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly 9
Tires 1 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 1 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Drive Motors
Torque Hubs 11 11
Functions/Controls 9
Platform Controls 5 5 6 6
3121180 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

Every 2
(Yearly) Years
Ground Controls 5 5 6 6
Function Control Locks, Guards, or Detents 1,5 1,5 5 5
Footswitch 1,5 5 5
Emergency Stop Switches (Ground & Platform) 5 5 5
Function Limit or Cutout Switch Systems 5 5
Capacity Indicator 5
Drive Brakes 5
Swing Brakes 5
Boom Synchronization/Sequencing Systems 5
Manual Descent or Auxiliary Power 5 5
Power System 9
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 5 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5
Hydraulic/Electric System 9
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 11 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operators and Safety Manuals in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Installed 21
Capacity Decals Installed, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
2-8 – JLG Lift – 3121180

SECTION 2 - GENERAL
INTERVAL

Every 2
(Yearly) Years
Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
3121180 – JLG Lift – 2-9

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30°F(-1°C)
WINTER 20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
ADDED
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. NOTE:
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C) 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES

CONSISTANTLY WITHIN SHOWN LIMITS
80° F (27° C)
EXXON UNIVIS HVI 26
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

70° F (21° C)
60° F (16° C)
HYDRAULIC SUMMER-GRADE WINTER-GRADE
50° F (10° C)
MOBIL DTE 13
SPECIFICATIONS FUEL FUEL

40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
AMBIENT TEMPERATURE
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
AMBIENT TEMPERATURE -13 -25
-22 -30
0 10 20 30 40 50 60
% OF ADDED KEROSENE
4150548 D
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-10 – JLG Lift – 3121180

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)
-10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
(82° C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

OF 100° F (38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
NOTE:
EXXON UNIVIS HVI 26
70° F (21° C)
60° F (16° C) 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
50° F (10° C)
HYDRAULIC CONSISTANTLY WITHIN SHOWN LIMITS
MOBIL DTE 13
SPECIFICATIONS 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C) C)
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) C)
-30° F (-34° C) C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C) C)
AMBIENT TEMPERATURE
4150548 D
Figure 2-2. Engine Operating Temperature Specifications - Ford
3121180 – JLG Lift – 2-11

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120°F(49°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
70°F(21°C)
ENGINE 60°F(16°C)
SPECIFICATIONS
50°F(10°C)
40°F(4°C)
30°F(-1°C)
20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10°F(-12°C)
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C)
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30°F(-34°C)
-40°F(-40°C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
(82°C) OR ABOVE.
180° F (82° C)
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

100° F (38° C)
90° F (32° C)
MOBIL 424 10W-30
80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26
60° F (16° C)
50° F (10° C)
HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
-20° F (-29° C)
-40° F (-40° C)
AMBIENT TEMPERATURE NOTE:
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTENTLY WITHIN SHOWN LIMITS
4150548 D
Figure 2-3. Engine Operating Temperature Specifications - Caterpillar
2-12 – JLG Lift – 3121180

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82° C) OR ABOVE.
180° F(82° C)

OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26
70° F (21° C)
60° F (16° C) NOTE:
50° F (10° C) HYDRAULIC
MOBIL DTE 13

SPECIFICATIONS CONSISTENTLY WITHIN SHOWN LIMITS
40° F (4° C)
30° F (-1° C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
-20° F (-29° C)
-40° F (-40° C)
AMBIENT TEMPERATURE
4150548 D
Figure 2-4. Engine Operating Temperature Specifications - GM
3121180 – JLG Lift – 2-13

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120°F(49°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
70°F(21°C)
ENGINE 60°F(16°C)
SPECIFICATIONS
50°F(10°C)
40°F(4°C)
30°F(-1°C)
20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10°F(-12°C)
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C)
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30°F(-34°C)
-40°F(-40°C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
(82°C) OR ABOVE.
180° F (82° C)

100° F (38° C)
90° F (32° C)
MOBIL 424 10W-30
80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26
60° F (16° C)
50° F (10° C)
HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
-20° F (-29° C)
-40° F (-40° C)
AMBIENT TEMPERATURE NOTE:
CONSISTENTLY WITHIN SHOWN LIMITS
4150548 D
Figure 2-5. Engine Operating Temperature Specifications - Perkins
2-14 – JLG Lift – 3121180

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS Tire Replacement
Tire Inflation JLG recommends a replacement tire be the same size,
ply, and brand as originally installed on the machine.
Pneumatic tire air pressure must be equal to air pressure Please refer to the JLG Parts Manual for part number of
stenciled on side of JLG product or rim decal for safe and approved tires for a particular machine model. If not using
proper machine operation. a JLG approved replacement tire, we recommend that
replacement tires have the following characteristics:
Tire Damage
• Equal or greater ply/load rating and size of original
Pneumatic Tires • Tire tread contact width equal or greater than original
JLG Industries, Inc. recommends when any cut, rip, or • Wheel diameter, width, and offset dimensions equal to
tear is discovered that exposes sidewall or tread area the original
cords in the tire, measures must be taken to remove the • Approved for the application by the tire manufacturer
JLG product from service immediately. Arrangements (including inflation pressure and maximum tire load)
must be made for replacement of the tire or tire assembly.
Unless specifically approved by JLG Industries Inc. do not
Polyurethane Foam Filled Tires
replace a foam filled or ballast filled tire assembly with a
JLG Industries, Inc. recommends when any of the follow- pneumatic tire. When selecting and installing a replace-
ing are discovered, measures must be taken to remove ment tire, ensure all tires are inflated to pressure recom-
the JLG product from service immediately and arrange- mended by JLG. Due to size variations between tire
ments made for replacement of tire or tire assembly: brands, both tires on the same axle should be identical.
• Smooth, even cut through cord plies which
exceeds 3" (7.5 cm) in total length. Wheel Replacement
• Tears or rips (ragged edges) in cord plies which Rims installed on each product model are designed for
exceeds 1" (2.5 cm) in any direction. stability requirements which consist of track width, tire
• Punctures which exceed 1" in diameter. pressure, and load capacity. Size changes such as rim
width, center piece location, larger or smaller diameter,
• Damage to bead area cords. etc., without written factory recommendations, may result
in unsafe stability conditions.
NOTE: If a tire is damaged but within above criteria, it must
be inspected daily to ensure damage does not
exceed allowable criteria.
Solid Flex Tires

JLG Industries, Inc. recommends when severe damage is
discovered that can cause any machine instability, mea-
sures must be taken to remove the JLG product from ser-
vice immediately. Arrangements must be made for
replacement of tire assembly.
Inspect tires for cracks, tears, wear, imbedded objects, or
other defects. Remove imbedded objects.
3121180 – JLG Lift – 3-1

Wheel Installation 2. Tighten nuts in the following sequence:
It is extremely important to apply and maintain proper

wheel mounting torque.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT

PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN
STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL
FROM AXLE. USE ONLY NUTS MATCHED TO CONE ANGLE OF
WHEEL.
Tighten lug nuts to proper torque to prevent wheels from

coming loose. Use a torque wrench to tighten fasteners. If
you do not have a torque wrench, tighten fasteners with a
lug wrench, then immediately have a service garage or
dealer tighten lug nuts to proper torque. Over-tightening
will break studs or permanently deform mounting stud
holes in wheels. The proper procedure for attaching
3. Torque to specifications shown in Table 3-1 below.
wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO Table 3-1. Wheel Torque Chart
NOT use a lubricant on threads or nuts.
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft-lb 100 ft-lb 170 ft-lb
(55 Nm) (130 Nm) (255 Nm)
4. Torque wheel nuts after first 50 hours of operation

and after each wheel removal. Check torque every 3
months or 150 hours of operation. Torque Hub
(Machines built Before S/N 0300071527).
3-2 – JLG Lift – 3121180

3.2 TORQUE HUB (MACHINES BUILT Tightening and Torquing Bolts

BEFORE S/N 0300071527) If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure bolts are not tightened
Roll, Leak, and Brake Testing beyond their specified torque.
Always roll and leak test Torque-Hub units before disas- The following steps describe how to tighten and torque
sembly and after assembly to make sure gears, bearings, bolts or socket head cap screws in a bolt circle:
and seals are working properly. The following information
1. Tighten (but do not torque) bolt “A” until snug.
briefly outlines what to look for when performing these
tests. 2. Go to the opposite side of the bolt circle and tighten
bolt “B” until equally snug.
NOTE: Brake must be released before performing roll test.
3. Crisscross around bolt circle and tighten remaining
Pressurize brake using Brake Leak Test procedure
bolts.
below or tighten bolts into piston through end plate
(See Brake Disassembly Procedure). 4. Use a torque wrench to apply specified torque to
bolt “A”.
NOTE: Bolts must be removed while performing brake 5. Using the same sequence, crisscross around bolt
release test. circle and apply equal torque to remaining bolts.
ROLL TEST
The roll test determines if gears are rotating freely and
properly. You should be able to rotate gears by applying
constant force to the roll checker. If you feel more drag in
gears only at certain points, gears are not rolling freely
and should be examined for improper installation or
defects. Some gear packages roll with more difficulty than
others. Do not be concerned if gears in your unit seem to
roll hard as long as they roll with consistency.
LEAK TEST (MAIN UNIT)
The leak test makes sure the unit is air tight. You can tell if
your unit has a leak if the pressure gauge reading on your
leak checking fitting starts to fall after unit is pressurized
and allowed to equalize. Leaks most likely occur at pipe
plugs, main seal, and wherever O-rings or gaskets are
located. Exact location of a leak can usually be detected
by brushing a soap and water solution around the main
seal and where O-rings or gaskets meet on unit exterior,
then checking for air bubbles. If a leak is detected in a
seal, O-ring, or gasket, the part must be replaced and unit
rechecked. Leak test at 10 psi for 20 minutes.
BRAKE TEST
FAILURE TO PERFORM THIS TEST MAY RESULT IN DAMAGED

OR INEFFECTIVE BRAKE PARTS.
Input Brake - 1,850 in-lb (208 Nm) Static,

225 psi (15.5 bar) Full Release
3000 psi (207 bar) maximum O-ring check.
If brake does not release at these pressure values, inspect
and repair, or replace brake.
3121180 – JLG Lift – 3-3

Main Disassembly 6. Remove Input Sun Gear (17) from Input Carrier Sub-
Assembly (3A).
1. Perform Roll Check, Leak Check and Brake Check if 7. Remove Input Carrier Sub-Assembly (3A) from
applicable prior to disassembling unit. Housing (1E).
2. Drain oil and note condition and volume. 8. Remove Output Sun Gear (8) from Output Carrier
3. Remove Input Coupling (9) from Spindle (1A) end of Sub-Assembly (4A).
unit. 9. Remove Input Shaft (7) from Output Carrier Sub-
4. Remove Cover Bolts (14) and Cover (6). Assembly (4A).
5. Remove O-ring (19) and Thrust Spacer (10) from 10. Remove Output Carrier Sub-Assembly (4A) from
Cover (6). Housing (1E).
6. Cover
9. Input Coupling
10. Thrust Spacer
14. Cover Bolts
19. O-ring
Figure 3-1. Main Disassembly Drawing 1
3-4 – JLG Lift – 3121180

7. Input Shaft
8. Output Sun Gear
17. Input Sun Gear
Figure 3-2. Main Disassembly Drawing 2
3121180 – JLG Lift – 3-5

Input Carrier Disassembly

1. Place Carrier (3A) on a press with spline end up.
Drive Planet Shaft (3E) out of Carrier (3A).
2. Slide Planet Gear (3F) and two Thrust Washers (3B)
out of Carrier (3A).
3. Remove 14 needle Bearings (3C) from bore of
Planet Gear (3F).
4. Repeat steps 1 through 3 for remaining planet
gears.
3A. Carrier
3B. Thrust Washers
3C. Needle Bearings
3E. Planet Shaft
3F. Planet Gear
Figure 3-3. Input Carrier Disassembly
3-6 – JLG Lift – 3121180

Output Carrier Disassembly 3. Slide Planet Gear (4F) and two Thrust Washers (4B)
out of Carrier (4A).
1. Using a small diameter punch, drive Roll Pin (4G)
4. Remove 15 needle Bearings (4C) from bore of
which holds Planet Shaft (4E) in Carrier (4A) into
Planet Gear (4F).
Planet Shaft (4E) until it bottoms.
5. Repeat steps 1 through 4 for remaining planet
gears.
MAKE SURE ROLL PIN HAS BOTTOMED OR CARRIER CAN BE 6. Remove Thrust Washer (4H) from Carrier (4A).
DAMAGED WHEN PLANET SHAFT IS REMOVED. 7. Remove Retaining Ring (4K) from Carrier (4A) using
retaining ring pliers. Pull Thrust Washer (4J) and
2. Remove Planet Shaft (4E) from Carrier (4A). Use a
Spring (4I) out of Carrier (4A).
small punch to remove Roll Pin (4G) from Planet
Shaft (4E).
4A. Carrier 4G. Roll Pin

4B. Thrust Washers 4H. Thrust Washer
4C. Needle Bearings 4I. Spring
4E. Planet Shaft 4J. Thrust Washer
4F. Planet Gear 4K. Retaining Ring
Figure 3-4. Output Carrier Disassembly
3121180 – JLG Lift – 3-7

Housing-Spindle Disassembly 5. Remove “A” position Bearing Cone (1D) from Bearing
Cup (1D) in Housing (1E).
1. Place unit on bench with Spindle (1A) end down.
6. Lift Housing (1E) off Spindle (1A).
7. If necessary, press Studs (1N) out of Housing (1E).
Locate Housing (1E) on Seal (1B) end.
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE
NEXT STEP IN THIS PROCEDURE. 8. Remove “B” position Bearing Cone (1D) from Spin-
dle (1A).
2. Using retaining ring pliers, remove Retaining Ring (1G) 9. Remove Seal (1B) from Spindle (1A).
from groove in Spindle (1A). 10. Using a soft steel rod, knock both Bearing Cups
3. Remove Bearing Spacer (1F) from top of Bearing (1C) out of Housing (1E).
Cone (1D).
4. While supporting unit on Housing (1E) flange, press
Spindle (1A) out of Housing (1E). Seal (1B) and “B”
position Bearing Cone (1D) should come out of
Housing (1E) with Spindle (1A).
1B. Seal 1F. Bearing Spacer

1C. Bearing Cups 1G. Retaining Ring
1D. Bearing Cone 1H. Wheel Stud
1E. Housing
Figure 3-5. Housing-Spindle Disassembly
3-8 – JLG Lift – 3121180

Spindle-Brake Disassembly NOTE: The Koenig Expander Pressure Plug (12) requires a
special installation tool. It is not recommended to
NOTE: This procedure applies only to units with integral remove this plug unless it is leaking. The installation
input brake (2). tool is available from KVT Solutioneering Group
(http://www.kvt-koenig.us) or their distributors as of
NOTE: For this procedure, use Brake Assembly Drawing, the date of this publication.
which shows proper balloon numbers for individual
brake components. In the following instructions, if
the number has a “-” between two numbers, it refers
Continued on next page.
to Brake Assembly Drawing only and NOT Torque
Hub Assembly Drawing.
1-A. Spindle 2-7. End Plate

12. Pressure Plug 2-8. Piston
2-1. Internal Circlip 2-9. Stator
2-2. O-ring 2-10. Spacer
2-3. Back-up Ring 2-11. Capscrew
2-4. O-ring 2-12. Rotor
2-5. Back-up Ring 2-13. Compression Spring
2-6. Internal Circlip
Figure 3-6. Spindle Brake Disassembly
3121180 – JLG Lift – 3-9

Input Carrier Sub-Assembly

SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE OR
SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION.
SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE OR
1. Compress Springs (2-13) by installing a minimum of SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION.
three M4 x 16mm Socket Head Cap Screws (2-11)
equally spaced through End Plate (2-7) and into Pis- 11. Apply a liberal coat of grease to bore of Input Planet
ton (2-8). Tighten screws incrementally until spring Gear (3F).
force is removed from Retaining Ring (2-6). 12. Line inside of Planet Gear (3F) with 14 Needle Roll-
2. Using a small pry bar or screwdriver, pry one end of ers (3C).
Retaining Ring (2-6) out of groove in Spindle (1A). 13. Set Carrier (3A) in an upright position.
Using pliers, pull Retaining Ring (2-6) out of groove.
14. Insert a Planet Shaft (3E) into planet shaft hole in
3. Back Socket Head Cap Screws (2-11) incrementally end of Carrier (3A) opposite splined end.
out of Piston (2-8) until spring force is relieved from
End Plate (2-7). 15. Place one Thrust Washer (3B) on end of Planet Shaft
(3E). Make sure flat faces towards inside of Carrier
4. Remove Socket Head Cap Screws (2-11) and End and make sure button fits in pocket inside Carrier (3A).
Plate (2-7) from brake cavity in Spindle.
16. Place one more Thrust Washer (3B) into Carrier (3A)
5. Remove Compression Springs (2-13) from Piston (2-8). and align as in Step 5.
6. Using an air hose, slowly and carefully pressurize
brake port in Spindle (1A) until Piston (2-8) comes NOTE: Grease may need to be applied to Thrust Washers
out of piston bore of Spindle (1A). Pull Piston (2-8) (3B) to hold them in place when installing planet
the rest of the way out of Spindle (1A) by hand. gear. Instead of grease, insert washers from ID of
carrier for buttons to fit in pockets of carrier.
7. Remove Backup Rings (2-3) & (2-5) and O-rings (2-
2) & (2-4) from Piston (2-8). 17. Following thrust washers, place Planet Gear (3F)
8. Remove Rotors (2-12) and Stators (2-9) from Spin- with needle rollers, into Carrier (3A) between Thrust
dle (1A). Washers (3B).
9. Invert Spindle (1A) and, using retaining ring pliers, 18. Push Planet Shaft (3E) through Planet Gear (3F) and
remove Retaining Ring (2-1). other Thrust Washer (3B) until it touches other side
of Carrier (3A).
10. Remove Spacer (2-10) from Spindle.
19. Press Planet Shaft (3E) to appropriate depth.
NOTE: If planet shaft locating tooling is not available, press

lightly on Planet Shaft (3E) and make sure not to
press Planet Shaft (3E) through small shoulder in
Carrier (3A). This shoulder is intended to keep planet
pin from working loose in that direction during oper-
ation. It is NOT intended to keep planet pin from
being pressed through carrier.
20. On side of Carrier (3A) where Planet Shaft (3E) was

inserted, stake Carrier (3A) in 3 places using a
punch and a hammer around Planet Shaft (3E) to
ensure shaft stays in place during operation.
21. Repeat Steps 1 through 10 for remaining Planet
Gears (3F).
3-10 – JLG Lift – 3121180

3A. Carrier
3B. Thrust Washers
3C. Needle Bearings
3E. Planet Shaft
3F. Planet Gear
Figure 3-7. Input Carrier Sub-Assembly
3121180 – JLG Lift – 3-11

Output Carrier Sub-Assembly
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-

OUS INJURY. ALWAYS WEAR EYE PROTECTION.
1. Place Spring (4I) in deep counterbore of Output Car-

rier (4A).
2. Place Washer (4J) on top of Spring (4I).
3. Install Retaining Ring (4K) on snap ring pliers and
place on top of Washer (4J). Compress Spring (4I)
until Retaining Ring (4K) is seated completely in
groove.
4. Apply a liberal coat of grease to bore of one Output
Planet Gear (4F).
5. Line inside of Planet Gear (4F) with 15 Needle Roll-
ers (4C).
6. Place Thrust Washer (4H) in shallow counterbore of
Output Carrier (4A).
7. Set Carrier (4A) in an upright position.
NOTE: Insert end of planet shaft that does NOT have roll pin
hole in carrier FIRST.
8. Insert a Planet Shaft (4E) into one of the planet shaft

holes on the Carrier (4A). Place one Thrust Washer
(4B) on end of Planet Shaft (4E). Make sure flat
faces towards inside of carrier button fits in pocket
inside Carrier (4A).
9. Following thrust washer, place Planet Gear (4F) with
needle rollers on Planet Shaft (4E).
10. Following planet gear, place one more Thrust
Washer (4B) on Planet Shaft (4E). Align Thrust
Washer (4B) in same manner described in Step 6.
11. Insert Planet Shaft (4E) through opposite planet
shaft hole on Carrier (4A). Use an alignment punch
or similar tool to align roll pin holes on Carrier (4A)
and Planet Shaft (4E).
12. Drive Roll Pin (4G) down into aligned roll pin holes.
Pin should be flush with OD of carrier.
13. Repeat Steps 4,5, & 8-13 for remaining Planet Gears
(4F).
3-12 – JLG Lift – 3121180

4A. Output Carrier

4B. Thrust Washer
4C. Needle Rollers
4E. Planet Shaft
4F. Planet Gear
4G. Roll Pin
4H. Thrust Washer
4I. Spring
4J. Washer
4K. Retaining Ring
Figure 3-8. Input Carrier Sub-Assembly
3121180 – JLG Lift – 3-13

Spindle-Brake Sub-Assembly 8. Grease large Backup Ring (2-3) and install in large-
diameter groove at bottom of Piston (2-8).
9. Grease large O-Ring (2-2) and install in large diame-
ter groove at bottom of Piston (2-8), on top of large
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI- Backup Ring (2-3).
10. Grease small O-Ring (2-5) and install in small diame-
This procedure applies only to units with integral input ter groove near top of Piston (2-8). Make sure O-
brake (2). Ring is seated in bottom of groove.
11. Grease small Backup Ring (2-4) and install in small
NOTE: For this procedure, use Brake Assembly Drawing,
diameter groove near top of Piston (2-8), on top of
which shows proper balloon numbers for individual
small O-Ring (2-5).
brake components. In the following instructions, if
the number has a “-” between two numbers, it refers NOTE: If piston comes pre-assembled with shipping bolts
to Brake Assembly Drawing only and NOT Torque (2-11), skip to Step 15.
Hub Assembly Drawing.
12. Insert Piston (2-8) into Spindle (1A) until it contacts
NOTE: The Koenig Expander Pressure Plug (12) requires a Stator (2-9).
special installation tool. It is not recommended to
13. Insert appropriate number of Springs (2-13) into Pis-
remove this plug unless it is leaking. The installation
ton (2-8) counterbore. Use brake spring chart below
tool is available from KVT Solutioneering Group
and a bill of materials for your particular model num-
(http://www.kvt-koenig.us) or their distributors as of
ber to determine number of springs.
the date of this manual.
BRAKE NUMBER
1. Install Pressure Plug (12) into Spindle (1A) using the BRAKE P/N
CODE OF SPRINGS
following procedure:
A 902337 12
• Clean hole in spindle using appropriate Loctite spray
B 902341 10
• Dip collar of plug in Loctite 290 or 680 (keep
unplugged portion of hole free of Loctite) C 902342 8
D 902343 6
• Using appropriate tool, install plug flush with surface of
spindle E 902345 9
2. Place Spindle (1A) with splined end facing down.

14. Place Pressure Plate (2-7) on top of Springs (2-13).
Using appropriate tool (See back of manual), install
Retaining Ring (2-1) into spindle groove within 15. Using snap ring pliers, install Retaining Ring (2-6)
splines. into groove in Spindle (1A) and on top of Pressure
Plate (2-7). Make sure Retaining Ring (2-6) is seated
3. Place Washer (2-10) on top of Retaining Ring (2-1).
properly in groove.
4. Place Stator (2-9) on top of Washer (2-10).
16. Remove Shipping Bolts (2-11) in brake pressure plate
5. Place Rotor (2-12) on top of Stator (2-9). to release springs in brake. Before removing bolts,
6. Repeat steps 3 & 4 until there are a total of 8 Stators (2-9) use Coupling (9 - Figure 3-11.) to center and align
and 7 Rotors (2-12) installed. Brake Rotors (2-12) with Spindle (1A).
7. Place Piston (2-8) with smaller O.D. end facing up.
3-14 – JLG Lift – 3121180

1-A. Spindle 2-7. End Plate

12. Pressure Plug 2-8. Piston
2-1. Internal Circlip 2-9. Stator
2-2. O-ring 2-10. Spacer
2-3. Back-up Ring 2-11. Capscrew
2-4. O-ring 2-12. Rotor
2-5. Back-up Ring 2-13. Compression Spring
2-6. Internal Circlip
Figure 3-8. Spindle Brake Sub-Assembly
3121180 – JLG Lift – 3-15

Housing-Spindle Sub-Assembly 9. Using retaining ring pliers, install Retaining Ring

(1G) into Spindle (1A) groove. Make sure ring is
NOTE: Spray a light film of oil on all component parts during completely seated in groove.
assembly.
NOTE: Extra bearing pre-load caused by pressing “A” Bear-
ing Cone (1D) must be removed. This should be
done by placing a flat piece of steel or a pressing
tool on the end of the spindle, and then lightly strik-
ing the tool with a piece of barstock. This should be
adequate to remove any additional bearing pre-load.
1. Press Bearing Cup (1C), position A, into Housing
(1E) using appropriate pressing tool (See back of DW2B INTEGRAL BRAKE CHECK
manual).
1. Connect hydraulic line from hand pump to brake
port.
2. Check brake is set by trying to rotate Input Shaft (7).
DO NOT USE EXCESSIVELY HIGH PRESSURE TO PRESS IN
This can be accomplished by installing an appropri-
STUDS OR HOUSING MAY CRACK. MAKE SURE HEAD OF STUD
ate tool (any tool that can locate on splines of the
CONTACTS FACE OF FLANGE ON HOUSING.
Input Coupling (9), such as a mating splined shaft)
2. Turn Housing (1E) over and place into pressing into Input Coupling (9)
base. Press nine Studs (1H) into Housing (1E). 3. Bleed brake. Increase hydraulic pressure gradually
while trying to rotate input until brake just starts to
NOTE: Spray a generous amount of oil on bearings during release. Note this pressure. Make sure pressure falls
installation. into appropriate range below:
3. Press Bearing Cup (1C), position “B”, into Housing
BRAKE JUST RELEASE
(1E) using “B” Bearing Cone pressing tool (see back BRAKE P/N
CODE PRESSURE RANGE (psi)
of manual).
A 902337 185-230
4. Place Bearing Cone (1D), into Bearing Cup (1C),
position “B”. B 902341 155-192
5. Grease Seal (1B) lip and press seal into Housing C 902342 125-155
(1E) using seal pressing tool (see back of manual) D 902343 93-115
until seal is flush with end of Housing. E 902345 132-172
6. Turn Housing (1E) over and lower onto Spindle (1A).
7. Install Bearing Cone (1D) into Bearing Cup (1C), 4. Increase pressure to 3,000 psi and hold for 30 sec-
position “A”. and lightly press on Bearing Cup using onds to check for leaks. Repair leaks if necessary.
the “A” Bearing Cone pressing tool (see back of NOTE: Make sure brake re-engages when pressure is
manual) while rotating Housing (1E) in both direc- released.
tions to seat bearings.
8. Place Bearing Spacer (1F) on top of Bearing Cone (1D). NOTE: When done, make sure Input Coupling (9) is cen-
tered in Spindle (1A) to make installation of motor
possible without release of brake.
3-16 – JLG Lift – 3121180

1B. Seal 1F. Bearing Spacer

1C. Bearing Cups 1G. Retaining Ring
1D. Bearing Cone 1H. Wheel Stud
1E. Housing
Figure 3-9. Housing-Spindle Disassembly
3121180 – JLG Lift – 3-17

Main Assembly 5. Place Input Carrier Sub-Assembly (3A) onto Output

Sun Gear (8) splines.
NOTE: All components should receive a generous amount 6. Grease O-Ring (19) and insert into groove in Cover
of lubricant oil as they are being assembled. Sub-Assembly (6).
1. Place Housing-Spindle Sub-Assembly on table with 7. Install Cover Sub-Assembly (6) onto Housing (1E)
Spindle (1A) side down. and install twelve Bolts (14) into Cover (6). Torque
bolts to 70-80 in-lbs.
2. Place Output Carrier Sub-Assembly into Housing
(1E) and onto Spindle (1A). 8. Attach ID Tag (15) onto unit. If Cover has knobs as
part of cover, peen top of each knob to form a head
3. Insert larger diameter splined end of Input Shaft (7) to hold on Tag. If no knobs, use drive screws.
through bore of Output Carrier Sub Assembly (4A) until
shoulder of Input Shaft (7) contacts Thrust Washer (4J) 9. Check disconnect, roll and leak check unit, leak
(See assembly drawing at back of manual). check brake, and check brake release pressure.
4. With modified spline end facing up, place Output

Sun Gear (8) into mesh with planet gears from Out-
put Carrier Sub-Assembly (4A).
7. Input Shaft
8. Output Sun Gear
17. Input Sun Gear
Figure 3-10. Main Assembly Drawing1
3-18 – JLG Lift – 3121180

6. Cover
9. Input Coupling
10. Thrust Spacer
14. Cover Bolts
19. O-ring
Figure 3-11. Figure 3-11. Main Assembly Drawing 2
3121180 – JLG Lift – 3-19

Figure 3-12. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2
3-20 – JLG Lift – 3121180

1A Spindle 4E Planet Shaft
1G Retaining Ring - Ext 4C Needle Bearing
12 Pressure Plug 4I Spring
16 O-ring Pipe Plug 4K Retaining Ring - Int
1F Thrust Washer 4G Roll Pin
1E Housing/Ring Gear 4B Thrust Washer
1N Stud 4H Thrust Washer
1C Tapered Bearing - Cup 4J Thrust Washer
1D Tapered Bearing - Cone 17 Sun Gear
1B Lip Seal 8 Sun Gear
3A Carrier 7 Input Shaft
3F Planet Gear 9 Coupling
3E Planet Shaft 6 Cover Subassembly
3C Needle Bearing 10 Thrust Spacer
3B Thrust Washer 15 Id Plate
4A Carrier 14 12 Pt Flange Bolt
4F Planet Gear 19 O-ring
Figure 3-13. Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2
3121180 – JLG Lift – 3-21

Figure 3-14. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2
3-22 – JLG Lift – 3121180

1A Spindle 4E Planet Shaft
2 Input Brake 4C Needle Bearing
1G Retaining Ring - Ext 4I Spring
12 Pressure Plug 4K Retaining Ring - Int
16 O-ring Pipe Plug 4G Roll Pin
1F Thrust Washer 4B Thrust Washer
1E Housing/ring Gear 4H Thrust Washer
1N Stud 4J Thrust Washer
1C Tapered Bearing - Cup 17 Sun Gear
1D Tapered Bearing - Cone 8 Sun Gear
1B Lip Seal 7 Input Shaft
3A Carrier 9 Coupling
3F Planet Gear 6 Cover Subassembly
3E Planet Shaft 10 Thrust Spacer
3C Needle Bearing 15 Id Plate
3B Thrust Washer 14 12 Pt Flange Bolt
4A Carrier 19 O-ring
4F Planet Gear
Figure 3-15. Assembly Drawing - With Integral Input Brake - Sheet 2 of 2
3121180 – JLG Lift – 3-23

3-24
– JLG Lift –
Figure 3-16. Assembly Tools - Bearing Cone Pressing - “B” Bearing
3121180
3121180
– JLG Lift –
Figure 3-17. Assembly Tools - Bearing Cone Pressing - “A” Bearing
3-25
3-26
– JLG Lift –
Figure 3-18. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings
3121180
Figure 3-19. Assembly Tools - Seal Pressing
3121180 – JLG Lift – 3-27

3-28
– JLG Lift –
Figure 3-20. Assembly Tools - Spacer - Brake Disc Installation
3121180
3121180
– JLG Lift –
Figure 3-21. Assembly Tools - Brake Retaining Ring Installation
3-29
3.3 TORQUE HUB (MACHINES BUILT AFTER Oil Information

S/N 0300071527) 1. 1. TYPE – EP90
Use EP90 for normal applications. For applications
Roll and Leak Testing where lubricant must meet special requirements, the
O.E.M can recommend a suitable substitute.
Always roll and leak test Torque-Hubs after assembly to
make sure that the unit’s gears and sealants are working 2. OIL TEMPERATURE
properly. The following information briefly outlines what to Continuous – 160° F (70° C) Intermittent – 200° F
look for when performing these tests. (95° C).
3. OIL CHANGE
ROLL TEST
Initial – After 50 hours or 50,000 revolutions of oper-
The purpose of a roll test is to determine if the unit’s gears ation. Subsequent – After 1000 hours or (1) year,
are rotating freely and properly. You should be able to whichever comes first.
rotate gears by applying a constant force to the roll
checker. If you feel more drag in the gears only at certain NOTE: Higher temperatures make it necessary to change oil
points, gears are not rolling freely and you should exam- more frequently.
ine them for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be 4. OIL FILL LEVEL AND VOLUME
concerned if gears seem to roll hard as long as they roll Unit mounted horizontal – half full. (See Diagram A.)
with consistency. Approximate volume - 17 oz. (0.5 1tr).
LEAK TEST MAIN DISASSEMBLY for “B” Drives

The purpose of a leak test is to make sure unit is air tight. 1. Turn hub (1G) on side, Remove coupling (14) from
You can tell if your unit has a leak if pressure gauge test wide end of spindle (1A).
reading starts to fall once you have pressurized the unit.
2. Mark location of shoulder bolt holes on outside of
Leaks usually occur at the main seal or wherever O-rings
ring gear and hub for easy realignment when
or gaskets are located. Usually, you can detect the exact
rebuilding. Remove four shoulder bolts (13) and 12
location of a leak by brushing a soap and water solution
bolts (12) from cover (6).
around the main seal and where O-rings or gaskets meet
unit exterior, then checking for air bubbles. If you detect a 3. Remove 16 flat washers (16) from cover (6).
leak in a seal, O-ring, or gasket, replace part immediately. 4. Lift cover sub-assembly (6) off ring gear (4). Set
cover on table with interior side facing up.
Tightening and Torquing Bolts
SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE

USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING.
NOT TIGHTEN BOLTS BEYOND THEIR TORQUE SPECIFICATION.
NEVER USE AN IMPACT WRENCH TO TIGHTEN SHOULDER 5. Remove O-ring (5) from counterbore around edge of
BOLTS. ALWAYS TIGHTEN A11 SHOULDER BOLTS BY HAND. cover (6A). Discard O-ring.
The following steps describe proper procedure for tighten- NOTE: If O-ring is not in cover counterbore, it is in ring
ing and torquing bolts or socket head capscrews in a bolt gear counterbore. Remove it from hub and discard.
circle.
6. Remove thrust washer (11) from counterbore in top
1. Tighten (but do not torque) bolt ”A” until snug.
of carrier (3A).
2. Go to opposite side of bolt circle and tighten bolt ”B”
7. Remove input gear (8) from middle of carrier sub-
until equally snug.
assembly (3).
3. Continue around bolt circle and tighten remaining
8. Lift ring gear (4) off hub (1G).
bolts.
9. Lift carrier sub-assembly (3) out of hub (1G).
4. Use a torque wrench to apply specified torque to
bolt ”A”. 10. Remove thrust spacer (9) from input shaft (7) in mid-
dle of spindle (1A).
5. Continue around bolt circle and apply equal torque
to remaining bolts. 11. Lift input shaft sub-assembly (7) out of middle of
spindle (1A). Stand input shaft (7A) on splined end.
3-30 – JLG Lift – 3121180

7. Turn hub (1G) over and lift it out of flange-support.

Remove bearing cup (1E) from counterbore in wide
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI- end of hub (1G).
OUS INJURY. ALWAYS WEAR EYE PROTECTION. 8. Turn hub (1G) over onto its small end. Remove two
pipe plugs (1J) from side of hub (1G).
12. Using retaining ring pliers, remove retaining ring
(7B) from groove on input shaft (7A). NOTE: If your unit does not have studs, skip this step.
13. Remove one spacer (7D), one spring (7C), and
other spacer (7D) from input shaft (7A). 9. Press nine studs (1N) out of stud holes in hub (1G).
14. Remove thrust washer (11) from around spindle 10. Hub-spindle disassembly is complete.
(1A).
Cover Disassembly
15. Lift internal gear (2) out of hub (1G).
1. Remove two bolts (6C) holding disconnect cap (6D)
16. Remove O-ring (5) from counterbore in hub (1G).
to cover (6A).
Discard O-ring.
2. Remove disconnect cap (6D) from on top of cover
17. Main disassembly for ”B” drives is complete.
cap (6B) and cover (6A).
Hub-Spindle Disassembly 3. Remove two bolts (6C) holding cover cap (6B) to
cover (6A).
NOTE: Start with large end of hub facing up and large end
4. Remove cover cap (6B) from cover (6A).
of spindle facing down.
5. Remove disconnect rod (6K) from cover cap (6B).
6. Pry O-ring (6F) out of groove inside cover cap (6B).
Discard O-ring.
7. Remove O-ring (6G) from flange of cover cap (6B).
Discard O-ring.
1. Remove retaining ring (1I) from around spindle (1A) 8. Remove pipe plug (6H) from cover (6A).
ia hub (1G). 9. Cover disassembly is complete.
2. Remove spacer (1H) from around spindle (1A) in
hub (1G). Carrier Disassembly
3. Set hub (1G), with small end/spindle facing down, NOTE: Discard old needle rollers and use new ones during
on something that will support the hub’s flange while reassembly.
it lifts hub up so spindle is not resting on anything.
Carefully press or hammer spindle (1A) down and 1. Using a punch and hammer, drive roll pin (3G) into
out of hub (1G). planet shaft (3E).
NOTE: If seal (1B) and bearing cone (1D) come out of hub
and rest on spindle, remove these parts from spindle
and set them aside. Discard seal. DRIVE ROLL PIN ALL THE WAY INTO PLANET SHAFT OR CAR-
RIER WILL BE DAMAGED WHEN PLANET SHAFT IS REMOVED.
4. If seal and bearing cone did not come out of small
end of hub (1G) when you pressed spindle out of 2. Using a punch and hammer, drive planet shaft (3E)
hub, remove seal (1B) and bearing cone (1D) from out of planet shaft hole in carrier housing (3A).
small end of hub (1G). Discard seal. 3. When you remove planet shaft (3E) from carrier
5. Bearing cone (1F) should be lying loose in wide end housing, one thrust washer (38), one cluster gear
of hub (1G). Remove bearing cone (1F) from inside (3F), and one more thrust washer (3B) will come off
hub (1G). planet shaft and come to rest inside carrier. Remove
these parts from inside carrier.
NOTE: Do not strike counterbore with punch if using a
4. Remove 16 needle rollers (3C) from inside one end
punch and hammer when removing bearing cup.
of cluster gear (3F). Discard needle rollers.
6. Remove bearing cup (1C) from counterbore in small 5. Remove one spacer (3D) from inside cluster gear (3F).
end of hub (1G). 6. Remove remaining 16 needle rollers (3C) from other
NOTE: Do not strike counterbore with punch if using a side of cluster gear (3F). Discard needle rollers.
punch and hammer when removing bearing cup.
3121180 – JLG Lift – 3-31

7. Repeat steps 1-6 to remove and disassemble two 4. Set carrier housing (3A) on table, sideways. Insert a
remaining cluster gears. planet shaft (3E), roll pin hole last, into one of the
8. At this point carrier disassembly is complete. planet shaft holes from roll-pin-holed side of carrier
housing (3A).
Assemble Carrier
1. Apply grease to inside of one cluster gear (3F) and line
one half of cluster gear with 16 needle rollers (3C).
5. Place thrust washer (3B) on end of planet shaft (3E)

inside carrier. Fit tang of thrust washer into slot on
inside edge of planet shaft hole.
2. Place spacer (3D) inside cluster gear (3F) so it rests

on top of needle rollers.
6. Following thrust washer, place cluster gear (3F),

large end toward roll pin hole in carrier housing, on
planet shaft (3E).
3. Line remaining half of cluster gear (3F) with 16 needle
rollers.
3-32 – JLG Lift – 3121180

7. Following cluster gear, place one more thrust 9. Drive roll pin (3G) into aligned roll pin holes in carrier
washer (3B) onto planet shaft (3E) through opposite housing (3A) and planet shaft (3E).
planet shaft hole in carrier housing (3A).
10. Repeat steps 1 thru 9 to assemble and install two

8. Use an alignment punch or similar tool to align roll pin remaining cluster gears.
holes in carrier housing (3A) and planet shaft (3E). 11. At this point carrier sub-assembly is complete.
3121180 – JLG Lift – 3-33

Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover
cap (6B) on cover (6A), aligning pipe plug hole in
1. Using disconnect rod, push O-ring (6F) into groove cover cap over pipe plug hole in cover.
inside cover cap (6B).
5. Place two cover cap bolts (6C) in any two bolt holes
2. Place O-ring (6G) onto cover cap (6B) so it rests 180° apart on cover cap (6B) and tighten bolts.
against flange of cover cap.
6. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm)

3. Insert disconnect rod (6E) into cover cap (6B). of torque to both bolts (6C).
3-34 – JLG Lift – 3121180

7. With large end down, place disconnect cap (6D) on 10. Apply a light coat of “Never-Seize” to pipe plug (6H)
cover cap (6B), aligning pipe plug hole in discon- and tighten it in pipe plug hole in cover (6A).
nect cap over pipe plug hole in cover cap.
8. Place two remaining bolts (6C) in bolt holes in dis- Hub-Spindle Sub-Assembly
connect cap (6D) and tighten bolts.
NOTE: Make sure cup sits square with counterbore before
pressing.
1. Set hub (1G) on large end. Press bearing cup (1C)

into counterbore in small end of hub (1G).
9. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm)

of torque to both bolts (6C).
2. Press nine studs (1N) in stud holes in hub (1G).
3121180 – JLG Lift – 3-35

3. Apply a light coat of “Never-Seize” to two pipe plugs 6. Press seal (1B) in small end of hub (1G).
(1J) and tighten them in two pipe plug holes in side
of hub (1G).
7. Oil spindle, then lower hub (1G) small end down,

onto spindle (1A).
NOTE: Make sure cup sits square with counterbore before
pressing.
4. Turn hub (1G) over to small end. Press bearing cup

(1E) into counterbore in deep end of hub (1G).
8. Press bearing cone (1F) on spindle (1A) in hub (1G).
5. Set hub (1G) on large end. Place bearing cone (1D)

into bearing cup (1C).
3-36 – JLG Lift – 3121180

9. Place spacer (1H) on spindle (1A) in hub (1G). Main Assembly
SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE

OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING.
1. Grease O-ring (5) and place it into counterbore in

hub (1G).
NOTE: O-ring may be stretched or pinched together to

make it fit into counterbore.
NOTE: Make sure retaining ring is securely seated in groove.
10. Place retaining ring (1I) over spacer onto spindle

(1A) in hub (1G).
2. Oil exposed surfaces inside hub (1G).
11. At this point hub-spindle sub-assembly is complete.
3121180 – JLG Lift – 3-37

3. Place internal gear (2) in hub (1G) so its internal 6. Place spring (7C) on smooth end of input shaft (7A).
splines mesh with external splines of spindle (1A).
Oil internal gear (2).
7. Place other spacer (7D) on smooth end of input

shaft (7A).
4. Place thrust washer (11) around spindle (1A) so it
rests on bottom of internal gear (2).
5. Stand input shaft (7A) on splined end. Place one UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-
spacer (7D) on smooth end of input shaft (7A). OUS INJURY. ALWAYS WEAR EYE PROTECTION.
8. Using retaining ring pliers, insert retaining ring (7B)

in groove on input shaft (7A) by compressing spring
and spacers together.
3-38 – JLG Lift – 3121180

9. With large splined end down, place input shaft sub- NOTE: This will hold punch marks in position while installing
assembly (7) into spindle (1A). carrier into hub.
10. Place thrust spacer (9) onto input shaft (7).

13. Place carrier sub assembly (3) and ring gear (4)
together into mesh with internal gear (2), aligning
“X” marked shoulder bolt hole in ring gear (4) over
one of the shoulder bolt holes in hub. Mark location
of shoulder bolt holes on outside of ring gear and
hub.
NOTE: You may lift ring gear off hub to align shoulder bolt
holes. Ring gear and carrier are installed together
only to keep punch marks on carrier in place.
11. Set carrier sub-assembly (3) on a flat work surface

so large ends of cluster gears (3F) face up. Locate
punch marks on face of each cluster gear (3F) and
position them at 12 o’clock.
14. With internal splines facing up (counterbore end facing

down), place input gear (8) into mesh with carrier sub-
assembly (3).
Figure 3-22. Cluster Gear Punch Marks
12. With “X” marked side facing up, place ring gear (4)
around cluster gears (3F).
3121180 – JLG Lift – 3-39

15. Oil all exposed surfaces inside hub (1G). Place 18. Place four flat washers (16) on top of bolt holes in
thrust washer (11) into counterbore in top of carrier. cover sub-assembly.
19. Place shoulder bolts (13) in four shoulder bolt holes

in cover (6) and hand-tighten.
SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY
WHEN INSTALLING O-RING.
16. Set cover (6A) on table, interior side up. Grease O-ring
(5) and place in counterbore around edge of cover (6A).
NOTE: O-ring may be stretched or pinched together to

make it fit counterbore.
20. Place remaining 12 flat washers (16) on remaining

bolt holes in cover (6).
17. Place cover sub-assembly (6) on ring gear (4). Align

pipe plug holes before disassembly.
3-40 – JLG Lift – 3121180

21. Place 12 bolts in remaining bolt holes in cover (6) 24. Roll test unit in clockwise and counterclockwise
and tighten. directions. Perform same number of turns in each
direction as the ratio of the unit. The ratio is the last
two digits of the model number on the unit’s ID tag.
22. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm).

Torque bolts (12) 18 to 25 ft-lb (25 to 34 Nm).
25. Leak test unit at a pressure of 5 psi (34.47 kPa) for
2 to 3 minutes.
23. Turn hub (1G) on its side. Insert coupling (14) into
end of spindle (1A).
26. At this point main assembly is complete.
3121180 – JLG Lift – 3-41

Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E).
The following specialized tools are used to assemble this

unit. Tool diagrams in this manual are intended for the
customer who may wish to have a tool made. All tools are
one piece and must be made from mild steel. All dimen-
sions are in inches.
NOTE: Tools may be carburized and hardened to improve

tool life. If this is done, tools must be ground on all
surfaces labeled with a “G” on the tool diagram.
1. T-118126 SEAL PRESSING TOOL FOR SEAL (1B).
4. T-109691 ASSEMBLY PRESSING TOOL FOR CONE (1F).
* These tools are for specific seals, cups or cones. There

is a specific tool for each cup and cone.
2. T-138903 ASSEMBLY PRESSING TOOL FOR CUP (1C).
3-42 – JLG Lift – 3121180

3.4 RE-ALIGNING TORQUE HUB INPUT

COUPLING UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE AND
SERIOUS INJURY. SPRING (18) IS HIGHLY COMPRESSED. DO
The following procedure applies to torque hubs with integral
NOT REMOVE SNA P RING (19) WITH OUT C OMPRESSING
brakes:
SPRING. ALWAYS WEAR EYE PROTECTION.
Equipment Required The following parts are needed to disassemble piston

1. Hydraulic power supply (hand pump) capable of block:
producing 200 psi (13.8 bar). 2 each 3/8" I.D. x 1 1/8" O.D. flat washers.
2. Hydraulic fittings to adapt hydraulic supply to brake 1 each 3/8" x 3 1/4" N.C. cap screw.
release port on hub.
1 each 3/8" N.C. nut.
Procedure Place one flat washer over 3/8" x 3 1/4" cap screw, and
1. Using appropriate fittings, connect a line from place this through center of piston block. Place other
hydraulic power supply to brake port. washer over cap screw and let it rest on three pins (16).
Screw on nut and compress spring inside piston block.
2. Pressurize brake release port to 155 - 200 psi
Use snap ring pliers to remove internal snap ring (19).
(10.6 - 13.8 bar) to release brake.
Remove bolt and two washers. Remove two washers (17),
3. Verify brake is released by rotating input coupling or spring (18), three pins (16), and pin keeper (15).
hub spindle. Once brake is released, input coupling
is free to re-align with drive motor. 1. Remove thrust race (10) from housing.
4. Install drive motor on hub. Release hydraulic pressure 2. Remove snap ring (1) from housing.
at brake release port. Coupling remains in position. 3. Remove shaft seal (2) from housing.
5. Disconnect hydraulic power supply and reconnect 4. Remove washer (3) from housing.
line to brake release port. 5. Remove drive shaft (7 or 25) from housing.
3.5 DRIVE MOTOR 6. Remove two snap rings (4), thrust washer (5), and
thrust bearing (6), from drive shaft.
NOTE: This procedure covers 2WD motors used on Cater- 7. On through shaft type assembly, remove snap ring (31)
pillar, Deutz, and Ford powered machines built prior and shaft seal (30) from back plate (27).
to S/N 0300100514).
Disassembly
1. Clean outside of unit thoroughly.
2. Clamp shaft in a protected jaw vise with back plate
end up.
3. Remove six cap screws (23 or 28 & 29) from back
plate (22 or 27).
4. Use a plastic mallet and tap back plate (22 or 27) to
loosen it.
5. Remove O-ring (21) from back plate.
6. Remove complete piston block assembly from
housing assembly.
7. Remove piston assemblies (11), spider (12), and
pivot (130 from piston block assembly.
8. Piston block assembly need not be disassembled
unless pins (16) or spring (18) is damaged.
3121180 – JLG Lift – 3-43

Inspection
1. Wash all parts thoroughly in a suitable solvent.
2. Examine needle bearings (8) and (20) in housing (9)
and back plate (22 or 27). If needles are free of
excessive play and remain in bearing cage, there is
no need to replace the bearing.
3. Inspect thrust washer (5) and thrust bearing (6). Sur-
faces should be free of any signs of wear or fretting.
4. Inspect spider (12) and pivot (13). Conical surfaces
should be free of wear and score marks.
5. Inspect piston (11). O.D. surface should be smooth
and free of scoring. Shoes should fit snug to piston.
Face of shoes should be flat and free of scoring and
flaking. Do not lap piston shoes.
6. Inspect piston block (14). Bore should be free of
scoring. Surfaces that contact back plate should be
smooth and free of grooves or metal build up. Do
not lap piston block.
7. Inspect thrust race (10). Surface should show no
signs of scoring or grooves.
8. Inspect flat surface on back plate (22 or 27). It
should be free of excessive scoring or metal build
up. Do not lap back plate.
9. Inspect drive shaft (7 or 25) for fretting in bearing
areas. Check spline area for twisted or broken teeth.
If keyed shaft, check for cracked or chipped keyway.
3-44 – JLG Lift – 3121180

1. Snap Ring 12. Spider 23. Capscrew

2. Shaft Seal 13. Pivot 24. Through Shaft
3. Washer 14. Piston Block 25. Drive Shaft
4. Snap Ring 15. Pin Keeper 26. Key
5. Thrust Washer 16. Pin 27. Backplate
6. Thrust Bearing 17. Washer 28. Capscrew
7. Drive Shaft 18. Spring 29. Capscrew
8. Needle Bearing 19. Snap Ring 30. Shaft Seal
9. Housing Assembly 20. Needle Bearing 31. Snap Ring
10. Thrust Race 21. O-ring 32. Rotating Kit Assembly
11. Piston Assembly 22. Backplate Assembly
Figure 3-23. Drive Motor
3121180 – JLG Lift – 3-45

Assembly 8. Lubricate thrust race (10) and install in housing

assembly.
1. Use filtered system oil to lubricate all critical moving 9. Install piston block assembly in housing assembly.
parts before assembly. The piston shoes must contact the thrust race (10).
2. Install one snap ring (4) in rear groove of drive shaft (7 Be sure all parts are in their proper position.
or 25). Install one thrust washer (5), thrust bearing (6), 10. Install new needle bearing (20) in back plate (22 or 27)
and second thrust washer (5) on drive shaft (7 or 25). if necessary.
Install second snap ring (4) in front groove on drive
11. Install new O-ring (21) on back plate (22 or 27).
shaft.
12. Install back plate (22 or 27) on housing.
3. Replace needle bearing (8) in housing (9) if neces-
sary. Install shaft in housing assembly (9) and install 13. Install six cap screws (23 or 28 & 29) and torque to
washer (3). Oil I.D. of new shaft seal (2) and press 15 to 18 ft-lb (21 to 25 Nm).
into position. Retain with snap ring (1). 14. On through shaft type assembly, install shaft seal (30)
4. Compress pin keeper (15) and install in spline area and snap ring (31) in back plate (27). Install key (26)
of piston block (14). in drive shaft (25).
5. Install three pins (16) in special grooves of spline
with head end of pin toward inside of block.
Drive Motor Troubleshooting
6. Install washer (17), spring (18), and second washer Pump must be isolated from motor to determine which
(17). Use two 3/8" I.D. washers and 3/8" x 3-1/4" cap unit is actually malfunctioning. A worn pump or worn
screw to compress spring. Retain with snap ring (19). motor give the same indication. It is advisable to first run a
Remove 3/8" x 3-1/4" cap screw and two washers. pressure and flow check on the pump to make sure it is
performing within operating specifications. The following
7. Install pivot (13), spider (12), and piston assemblies (11) trouble shooting suggestions are based on assumptions
in piston block assembly. pump has been flow and pressure checked and is within
operating specifications.
Table 3-2. Motor Trouble Shooting
Possible Trouble Cause Remedies

Motor turns while unloaded but A. Soored back plate. A. Remove back plate and examine surface condition of flat area; if scored, replace
slows down or stops when load is back plate. Do not lap
applied
B. Scored or worn piston shoes. B. Disassemble motor, examine condition of shoes on pistons as a complete set if
necessary. Do not lap.
C. Low relief valve pressure. C. Check relief valve for proper pressure setting; adjust or replace relief valve.
Motor will not turn. A. Severely scored back plate. A. Disassemble motor completely. Inspect all parts, replace all worn parts, Clean
all parts, replace all worn parts and flush hydraulic system.
Motor free wheels. A. Oil flow and pressure shut off When the hydraulic system is shut off, either by shutting off the engine on a closed
going to motor. loop system or returning the control valve spool to neutral on a open center system,
the motor will free wheel after it has leaked off. This is inherent in the design. On a
closed loop or propulsion system, the motor will not free wheel as long as charge
pressure is maintained to and from the motor.
Excessive case drain flow. A. Excessive internal wear in motor. Disassemble motor, inspect parts and replace as necessary. Case drain flow
should not exceed 1.5 GPM at full pressure.
3-46 – JLG Lift – 3121180

3.6 DRIVE MOTOR Shaft Seal Replacement

NOTE: This procedure covers: REMOVAL
1. Remove snap ring (1) and support washer (2).
2WD motors used on GM powered machines.
1
2WD motors used on Caterpillar, Deutz, and Ford
powered machines S/N 0300100514 to Present.
2
All 4WD motors.
3
Description
Drive motors are low to medium power, two-position axial
piston motors incorporating an integral servo piston. They
are designed for operation in open and closed circuit
applications. The standard control is a direct acting single
line hydraulic control. The integral servo piston controls
motor displacement.
Motors are spring biased to maximum displacement and 1. Snap Ring
hydraulically shifted to minimum displacement. Minimum 2. Support Washer
and maximum displacement can be set with fixed internal 3. Shaft Seal
stops. The large diameter servo piston allows smooth
acceleration and deceleration with relatively large circuit Figure 3-25. Removing Shaft Seal
orificing.
NOTE: To avoid damaging shaft during removal, install a
Bias spring large sheet metal screw into chuck of a slide ham-
Servo piston
Minimum mer. Drive screw into seal surface and use slide
Angle Swashplate hammer to pull seal.
Stop
2. Carefully pry out and discard shaft seal (3).
Output INSPECT COMPONENTS
Cylinder Shaft
Inspect new seal, motor housing seal bore, and sealing
Block area on shaft for rust, wear, and contamination. Polish
shaft and clean housing if necessary.
INSTALLATION
Shaft
Seal 1. Cover shaft splines with an installation sleeve to pro-
Piston tect shaft seal during installation.
Endcap Slipper Bearing
Valve plate 2. Install a new shaft seal (3) with cupped side facing
motor. Press seal into housing until it bottoms out.
Figure 3-24. Drive Motor Cross Section
Press evenly to avoid binding and damaging seal.
3. Install seal support washer (2).
4. Install snap ring (1).
5. Remove installation sleeve.
3121180 – JLG Lift – 3-47

Loop Flushing Valve INSPECT COMPONENTS
REMOVAL Inspect new O-rings and sealing area for rust, wear, or
contamination. Check springs and poppet for wear.
1. Use an 11/16" internal hex wrench to remove plug
(1) and (2). INSTALLATION
6 1. Install orifice poppet (13).
9
2. Install shift spool (12).
11
2
3. Install spring retaining washers on springs (10 and 11).
11/16 in
27 ft.lbs. 4. Carefully install centering springs (7, 8, and 9).
(37 Nm)
5. Install new O-rings (6, 4, and 5).
6. Use a 1/4" hex wrench to torque plug (3) to 20 ft-lb
(27 Nm).
7. Use an 11/16" internal hex and torque plugs (2 and 1)
to 27 ft-lb (37 Nm).
10 12
8
4
1 13
11/16 in
27 ft.lbs.
(37 Nm) 7
5/8 in
5 3 20 ft.lbs.
(27 Nm)
1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer
Figure 3-26. Loop Flushing Spool
2. Use a 1/4" in hex wrench to remove plug (3).

3. Remove O-rings (4, 5, and 6).
4. Use pliers to remove centering springs (7, 8, and 9).
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).
3-48 – JLG Lift – 3121180

Troubleshooting
Table 3-3. Excessive Noise and/or Vibration
Item Description Action

Fill reservoir to proper level and ensure oil supply to motor is
Check oil level in reservoir Insufficient hydraulic fluid could lead to cavitation that would
adequate and lines are unobstructed.
and oil supply to motor. cause system noise.
Air trapped in system lines or motor could result in cavitation Ensure system lines and components are purged of air.
Check for air in system.
that would cause system noise.
Inspect output shaft cou- A loose or incorrect shaft coupling will produce vibrations Ensure correct coupling is used and fits properly on shaft.
plings. that could result in system noise.
Inspect output shaft align- Misaligned shafts create excessive frictional vibration that Ensure that the shafts are properly aligned.
ment. could result in system noise.
Hydraulic oil viscosity Viscosity above acceptable limits will result in cavitation that Replace hydraulic oil with appropriate fluid for operating
above limits. would lead to system noise. conditions.
Table 3-4. System Operating Hot

Check oil level in reservoir Insufficient amount of hydraulic fluid will not meet system Fill reservoir to proper level.
and oil supply to pump. cooling demands.
Ensure heat exchanger is receiving adequate air flow and is
Inspect heat exchanger If heat exchanger fails or becomes obstructed, it may not
in good operating condition. Repair or replace as necessary.
(if equipped). meet system cooling demands.
If a system relief valve becomes unseated for an extended Repair or replace any malfunctioning relief valves and verify
Check system relief valves. period of time or fails for any other reason, the system could loads on machine are not excessive.
become overheated.
Table 3-5. Won’t Shift or Slow to Start

Obstructed or restricted flow through the servo control sig- Ensure signal lines are not obstructed or restricted and that
Check signal line to servo
nal lines could result in slow shift or no shift conditions signal pressure is adequate to shift the motor.
control port.
within the motor.
Check correct supply and
Supply and drain orifices determine motor shift rate. The Ensure proper control orifices are installed in motor and
drain orifices are properly
smaller the orifice, the longer time it takes to shift the motor. check they are not obstructed. Clean or replace as needed.
installed and not
Obstruction also increases shift times.
obstructed.
3121180 – JLG Lift – 3-49

Disassembly
17
NOTE: Removal of endcap voids warranty.
19
During assembly, coat all moving parts with a film of

clean hydraulic oil. This ensures parts are lubri-
cated during start-up.
15
Replace all O-Rings and gaskets. Lightly lubricate
O-rings with clean petroleum jelly prior to assembly.
14
6
9
5 11
2
7 21
13
3
18
10 12
8
4
1 16
16
20
14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
1. Plug 5. O-ring 9. Spring 12. Shift Spool 16. Control Line Plug 20. Drain Plug
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet 17. Control Line Plug 21. Work Port Plug
3. Plug 7. Spring 11. Washer Figure 3-28. Plugs, Fittings, and Speed Sensor
4. O-ring 8. Spring
Figure 3-27. Loop Flushing Spool 8. Remove all fittings from unit. Discard O-rings.
9. Using an 11/16" hex wrench, loosen speed sensor
1. Using a 11/16" wrench, remove plug (1) and (2). lock nut (14) if equipped and remove speed sensor.
2. Using a 5/8" hex wrench, remove plug (3). Units without speed sensor have an O-ring plug (15)
installed in that location; remove it with a 1/4" inch
3. Remove O-rings (4, 5, and 6).
internal hex wrench.
4. Using pliers, remove centering springs (7, 8, and 9).
10. Using a 1/4" internal hex wrench, remove control line
5. Remove spring retaining washers (10 and 11). plugs (16, 17). Discard O-rings. Using a 3 mm hex
6. Remove shift spool (12). wrench, remove cavity plug (18) (if equipped with
two-line control), from X2 cavity.
7. Remove orifice poppet (13).
11. Using a 5/16" internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.
12. If equipped with axial ports, use a 9/16" an internal
hex wrench and remove work port plugs (21). Discard
O-rings.
3-50 – JLG Lift – 3121180

25
22
27
30
23 29
29
26
24
28
22. Screw
23. End Cap 25. Valve Plate
24. O-ring 26. End Cap
27. O-ring
Figure 3-29. End Cap 28. O-ring
29. Angle Stop
13. Using an 8 mm internal hex wrench, remove endcap 30. Servo Spring
screws (22).
Figure 3-30. Valve Plate & Rear Shaft Bearing
14. Remove endcap (23). Remove O-ring (24) from
housing or endcap.
NOTE: When endcap screws are removed, pressure from

servo spring will cause endcap to bind on shaft. DO NOT SCRATCH VALVE PLATE SURFACE.
Press down on portion of endcap covering servo pis-
ton and hold endcap level while removing. 15. Remove valve plate (25) and timing pin (26) from
endcap.
NOTE: Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate
part number are stamped on its surface.
16. Remove and discard O-rings (27, 28).

17. Remove rear shaft bearing (29) from endcap with a
bearing puller.
DO NOT DRIVE BEARING PAST REAR SHAFT JOURNAL.

BEARING MAY BECOME TRAPPED ON SHAFT AND DAMAGED.
NOTE: Bearing may be difficult to remove with a puller. Try

this as an alternative: Pack bearing cavity with heavy
grease. After shaft is removed, insert it into bearing
cavity and tap lightly with a soft mallet on the splined
end. Grease will force out bearing.
3121180 – JLG Lift – 3-51

18. Remove minimum angle stop (29) and servo spring (30) 20. Turn housing over and remove snap ring (32) retaining
from housing. shaft seal, and support washer. Remove support washer
(33) and carefully pry out shaft seal (34). Discard seal.
NOTE: To avoid damaging shaft during seal removal. Install

a large sheet metal screw into the chuck of a slide
hammer. Drive screw into seal surface and use slide
31 hammer to pull seal.
36
35
37
31. Cylinder Kit Assembly
Figure 3-31. Cylinder Kit

38
19. Turn housing on its side and remove cylinder kit

assembly (31). Set assembly aside, being careful
not to scratch the running surface.
NOTE: Grooves on surface of cylinder kit identify its dis-

placement: 35. Inner Snap Ring
36. Snap Ring
Table 3-6. Displacement Identifiers 37. Bearing
38. Shaft
# of Grooves Frame L Frame K
1 25 38 Figure 3-33. Shaft & Front Bearing
2 30 45 21. Remove inner snap ring (35) and shaft/bearing
3 35 -- assembly.
22. Remove snap ring (36) retaining shaft front bearing.
Pull bearing (37) off shaft (38).
32
33
34
32. Snap Ring

33. Support Washer
34. Shaft Seal
Figure 3-32. Shaft Seal
3-52 – JLG Lift – 3121180

Lift here
44
39
45
47
40
48
43
42
49
41
46
53
52
39. Swashplate 50
40. Servo Piston
41. Piston Seal 51
42. O-ring
43. Journal Bearings
Figure 3-34. Swash Plate & Servo Piston

44. Piston 49. Retaining Ring
23. Turn housing over and remove swashplate (39) by 45. Slipper Retainer 50. Block Spring Washer
lifting on end opposite servo lever. 46. Cylinder Block 51. Spiral Retaining Ring
47. Ball Guide 52. Block Spring
24. Remove servo piston (40). Remove piston seal (41)
48. Holddown Pins 53. Inner Block Spring Washer
and O-ring (42) from servo piston. Discard seal and
O-ring. Figure 3-35. Cylinder Kit Disassembly
25. Remove journal bearings (43) from housing. If bear-
ings will be reused, note location and orientation of 26. Remove pistons (44) and slipper retainer (45) from
each bearing for reassembly. cylinder block (46).
NOTE: Pistons are not selectively fitted. Units with high

hourly usage may develop wear patterns. Number
pistons and bores for reassembly if they will be
reused.
27. Remove ball guide (47), hold-down pins (48), and

retaining ring (49) from cylinder block.
NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems
with the block spring.
3121180 – JLG Lift – 3-53

RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING

REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO
REMOVE SPIRAL RETAINING RING. RELEASE PRESSURE SLOWLY
AFTER RETAINING RING IS REMOVED.
28. Turn block over. Using a press, apply pressure on block

spring washer (50) to compress block spring enough to
safely remove spiral retaining ring (51). Maintain pres- SLIPPERS
sure and unwind spiral retaining ring (51). Carefully Inspect running surface of slippers. Replace piston
release pressure and remove outer block spring assemblies with scored or excessively rounded slipper
washer (50), block spring (52), and inner block spring edges. Measure slipper foot thickness. Replace piston
washer (53) from cylinder block. assemblies with excessively worn slippers. Check slipper
axial end-play. Replace piston assemblies with excessive
Inspection end-play.
After disassembly, wash all parts (including end-cap and Minimum slipper foot thickness and maximum axial end-
housing) thoroughly with clean solvent and allow to air play are shown in table 3.7.
dry. Blow out oil passages in housing and endcap with
compressed air. Conduct inspection in a clean area and Table 3-7. Slipper Foot Thickness & End Play
keep all parts free from contamination. Clean and dry
parts again after any rework or resurfacing. Measurement L Frame K Frame
PISTON mm 2.71 4.07

Slipper Foot Thickness
(in.) (0.11) (0.16)
Inspect pistons for damage and discoloration. Discolored 0.15
pistons may indicate excessive heat. Do not reuse. Piston/Slipper End Play
(0.006)
CYLINDER BLOCK
Measure cylinder block height. Replace blocks worn
beyond minimum height specification. Inspect running
surface of cylinder block. Replace or resurface worn or
scratched blocks. Blocks may be resurfaced if resurfacing
will not reduce block height below minimum specification
shown in Table 3-8, Cylinder Block Measurements.
Table 3-8. Cylinder Block Measurements
Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
(A)
0.002 0.002 0.002 0.002 0.002
Cylinder Block Surface Flatness
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)
3-54 – JLG Lift – 3121180

BALL GUIDE AND SLIPPER RETAINER SWASHPLATE AND JOURNAL BEARINGS

Inspect ball guide and slipper retainer for damage, discol- Inspect running face, servo ball-joint, and swashplate jour-
oration, or excessive wear. A discolored ball guide or slip- nal surfaces for damage or excessive wear. Some material
per retainer indicates excessive heat. Do not reuse. transfer may appear on these surfaces and is acceptable
providing surface condition meets specifications shown.
Measure swashplate thickness from journals to running
Slipper retainer face. Replace swashplate if damaged or worn beyond
minimum specification.
Ball guide
0.0025 mm
[0.0001 in]
VALVE PLATE 25.8 mm

LV [1.015 in]
Valve plate condition is critical to motor efficiency. Inspect
KV 24.6 mm
valve plate surfaces for excessive wear, grooves, or [0.969 in]
scratches. Replace or resurface grooved or scratched Thickness equality
side to side:
valve plates. Measure valve plate thickness and replace if 0.05 mm [0.002 in]
worn beyond minimum specification. Valve plate can be
resurfaced if finished thickness is not below minimum
specification shown in drawing.
3.83 mm [0.151 in] min.
0.025 mm
[0.001 in] Inspect journal bearings for damage or excessive wear.
Replace journal bearings if scratched, warped, or exces-
sively worn. Polymer wear layer must be smooth and intact.
SHAFT BEARINGS
0.0076 mm
Inspect bearings for excessive wear or contamination.
[0.00030 in]
convex max Rotate bearings while feeling for uneven movement. Bear-
ings should spin smoothly and freely. Replace bearings
that appear worn or do not rotate smoothly.
3121180 – JLG Lift – 3-55

SHAFT Assembly
Inspect motor shaft. Look for damage or excessive wear 1. Install new O-ring (1) and piston seal (2) to servo
on output and block splines. Inspect bearing surfaces and piston (3). Install piston seal over O-ring.
sealing surface. Replace shafts with damaged or exces-
sively worn splines, bearing surfaces, or sealing surfaces. NOTE: Installing piston seal stretches it, making it difficult to
install servo piston in its bore. Allow 30 minutes for
SERVO PISTON AND MINIMUM ANGLE STOP seal to relax after installation. To speed up seal relax-
Inspect minimum angle stop, servo piston head, and ation, compress seal by installing piston head in
servo piston ball-socket for damage or excessive wear. servo cavity in end-cap and let it stand for at least
Replace if necessary. five minutes.
2
3
1
LOOP FLUSHING SPOOL
Inspect loop flushing spool. Check for cracks or damage.
Replace if necessary.
3
1. O-ring
2. Piston Seal
3. Servo Piston
Figure 3-36. Servo Piston
2. After piston seal has relaxed, lubricate and install

servo piston into housing bore. Align piston with ball
socket facing inside of housing.
COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS

INJURY. COMPRESSING BLOCK SPRING REQUIRES ABOUT 80 TO
90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE
SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL SPIRAL
RETAINING RING. RELEASE PRESSURE SLOWLY AFTER RETAINING
RING IS INSTALLED.
3-56 – JLG Lift – 3121180

3. Install inner block spring washer (4), block spring 6. Install journal bearings (13) into housing seats. Use
(5), and outer washer (6) in cylinder block. Using a assembly grease to keep bearings seated during
press, compress block spring enough to expose assembly. Ensure locating nubs drop into cavities in
retaining ring groove. Wind spiral retaining ring (7) seats. If reusing bearings, install them in original
into cylinder block. location and orientation. Lubricate journal bearings.
11 14
13
12
10
9
8 13
5
13. Journal Bearings
14. Swash Plate
6
Figure 3-38. Swash Plate and Journal Bearing
7
7. Install swashplate (14) in housing. Tilt swashplate
and guide servo lever ball into its socket in servo pis-
ton rod. Ensure swashplate seats into journal bear-
4. Block Spring Washer 9. Holddown Pins ings and moves freely. Lubricate swashplate running
5. Block Spring 10. Ball Guide surface.
6. Outer Washer 11. Piston
7. Spiral Retaining Ring 12. Slipper Retainer
8. Retaining Ring
Figure 3-37. Cylinder Kit Assembly
4. Turn block over and install retaining ring (8), hold-

down pins (9), and ball guide (10) to cylinder block.
IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK

BORES.
5. Install pistons (11) to slipper retainer (12). Install pis-

ton/retainer assembly in cylinder block. Ensure con-
cave surface of retainer seats on the ball guide.
Lubricate pistons, slippers, retainer, and ball guide
before assembly. Set cylinder kit aside on a clean
surface until needed.
3121180 – JLG Lift – 3-57

8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated.
bearing onto shaft with lettering facing out. Lubricate Install cylinder kit (19) onto shaft. Install with slippers
bearing rollers. Install snap-ring (17) on shaft. facing swashplate. Rock shaft to align block splines
and slide cylinder kit into place. Orient motor with
shaft pointing downward and verify cylinder kit,
swashplate, journal bearings, and servo piston are
all secure and properly installed.
19
15
16
19. Cylinder Kit
Figure 3-40. Cylinder Kit Installation

17
11. Lubricate and install servo spring (20), and minimum
18
angle stop (21) into housing bore.
15. Front Shaft Bearing

16. Shaft
17. Snap Ring
18. Snap Ring
Figure 3-39. Shaft and Front Bearing 21
9. While holding swashplate in place, turn housing on 20

its side. Install shaft/bearing assembly into housing
from flange end. Install snap ring (18).
20. Servo Spring

21. Minimum Angle Stop
Figure 3-41. Servo Spring and Minimum

Angle Stop
3-58 – JLG Lift – 3121180

12. Press rear shaft bearing (22) into endcap. Install 15. Install endcap (25) on housing with endcap screws
bearing with letters facing out. Press until bearing (26). Check endcap properly seats on housing with-
surface is 0.08 ±0.01 in (2 ±0.25 mm) above end- out interference. Improper assembly of internal com-
cap surface. ponents may prevent endcap from seating properly.
Ensure O-rings seat properly when installing endcap.
22 3 mm
23 [0.12 in]
2 mm 26
[0.08 in]
8 mm
35-45 ft.lbs.
(47-61 Nm)
23
22
25
24
23
25. End Cap

26. Screw
22. Rear Shaft Bearing
23. Timing Pin Figure 3-43. End Cap
24. Valve Plate
16. Using an 8 mm internal hex wrench, tighten endcap
Figure 3-42. Valve Plate and Rear Bearing screws. Tighten screws in opposite corners slowly
and evenly to compress servo spring and properly
13. Install timing pin (23) into bore in endcap. Install pin seat endcap. Torque endcap screws 35 to 45 ft-lb
with groove facing toward or away from shaft. Press (47-61 Nm).
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
17. Before installing shaft seal, ensure shaft turns
above endcap surface.
smoothly with less than 120 in-lb (13.5 Nm) of force.
14. Install valve plate (24) on endcap. Install valve plate If shaft does not turn smoothly within specified force,
with yellow surface toward cylinder block. Align slot disassemble and check unit.
in valve plate with timing pin. Apply a liberal coat of
assembly grease to endcap side of valve plate to
keep it in place during installation.
3121180 – JLG Lift – 3-59

18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to housing. Refer
a new shaft seal (27) with cup side facing motor. to drawing below for wrench sizes and installation
Press seal into housing until it bottoms out. Press torques.
evenly to avoid binding and damaging seal. Install 1/4 in
5/16 in
seal support washer (28) and snap ring (29). 63 ft.lbs. 33 ft.lbs.
(85 Nm) (45 Nm)
29
28
27
9/16 in
125 ft.lbs.
(170 Nm)
27. Shaft Seal 3 mm

28. Seal Support Washer 1.5 to 2.5 ft.lbs.
(2.03 to 3.39 Nm)
29. Snap Ring
Figure 3-44. Shaft Seal

1/4 in
33 ft.lbs.
(45 Nm)
5/16in
63 ft.lbs.
(85 Nm)
Figure 3-45. Plugs and Fittings Installation
3-60 – JLG Lift – 3121180

20. Install orifice poppet (30). Initial Start-up Procedures

21. Install shift spool (31).
Follow this procedure when starting up a new motor or
22. Install spring retaining washers on springs (32 and 33). after reinstalling a motor.
23. Carefully install centering springs (34, 35, and 36). Prior to installing motor, inspect for damage incurred dur-
24. Install new O-rings (37, 38, and 39). ing shipping or storage. Make certain all system compo-
25. Using a 5/8" wrench, torque plug (40) to 20 ft-lb (27 Nm). nents (reservoir, hoses, valves, fittings, heat exchanger,
etc.) are clean before filling with fluid.
26. Using a 11/16" wrench, torque plugs (41 and 42) to
27 ft-lb (37 Nm). 1. Fill reservoir with recommended hydraulic fluid.
Always filter fluid through a 10 micron filter when
37 pouring into reservoir. Never reuse hydraulic fluid.
36
39 33 2. Fill inlet line leading from pump to reservoir. Check
41
34
11/16 in
inlet line for properly tightened fittings and be certain
30
27 ft.lbs.
it is free of restrictions and air leaks.
40
(37 Nm)
5/8 in 3. Fill pump and motor housing with clean hydraulic
20 ft.lbs. fluid. Pour filtered oil directly into upper most case
(27 Nm)
drain port.
32
31 4. Install case drain lines into upper most case drain
35 ports to ensure pump and motor stay filled with oil.
38
5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge
42 pressure gauge port of pump to monitor system
11/16 in pressure during start up.
27 ft.lbs.
(37 Nm) 6. Watch pressure gauge and run engine at lowest
possible speed until system pressure builds to nor-
mal levels (minimum 160 psi [11 bar]). Once system
pressure is established, increase to full operating
speed. If system pressure is not maintained; shut
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug down engine, determine cause, and take corrective
31. Shift Spool 35. Spring 38. O-ring 41. Plug action.
32. Spring 36. Spring 39. O-ring 42. Plug 7. Operate hydraulic system at least fifteen minutes
33. Spring under light load conditions.
Figure 3-46. Loop Flushing Spool 8. Check and adjust control settings as necessary after
installation.
9. Shut down engine and remove pressure gauge.
Replace plug at charge pressure gauge port.
10. Check fluid level in reservoir; add clean filtered fluid
if necessary. Motor is now ready for operation.
3121180 – JLG Lift – 3-61

Table 3-9. Chassis Torque Values
Ft-Lb Nm
A 120 163
B 240 325
C 170 230
This figure applies to USA built machines prior to S/N 0300107512 and D 140 190
Belgium built machines prior to S/N 1300003222
E 165 224
F 35 47
Figure 3-47. Chassis Torque Values - Sheet 1 of 2
3-62 – JLG Lift – 3121180

Table 3-10. Chassis Torque Values
Ft-Lbs. Nm
A 120 163
B 240 325
C 170 230
D 85 115
E 165 224
This figure applies to USA built machines S/N 0300107512 to Present and Belgium built machines S/N 1300003222 to Present
Figure 3-47. Chassis Torque Values - Sheet 2 of 2
3121180 – JLG Lift – 3-63

3.7 ADJUSTMENT PROCEDURE FOR 1. Make sure machine is on a level surface.
LOCKOUT VALVE 2. Center boom over rear axle to make sure cam valve
in the rotary coupling is depressed.
11. With turntable centered, adjust bracket with washers 3. Place chocks under tires to ensure machine does
to push plunger in 5/16" ± 1/16" (7.9 ± 1.6 mm). not move. Disable machine brakes by disconnecting
brake solenoid(s) on brake valve.
4. Use suitable containers to catch excess hydraulic
fluid. Place containers under each lockout cylinder.
5. Open one bleeder screw at a time.
6. Start engine, position drive control lever forward or
reverse.
7. Close bleeder screws when all air is dissipated
(bled).
8. Reconnect brake solenoid(s) and remove wheel
chocks.
9. Perform oscillating axle lockout test.
10. If necessary, repeat steps 1 thru 7.
Lockout Cylinder Bleeding (Ram Cylinders)

NOTE: The following procedure is for machines built in the
USA S/N 0300107512 to present and machines built
in Belgium S/N 1300003222 to present.
1. Position turntable to normal stowed position so axle

is free to oscillate. Drive charge pressure will pass
1. Washer through lockout valve built into swivel and down to
2. Bracket pilot section of holding valves on cylinders. This will
3. Lockout Valve automatically purge air from pilot section of circuit.
2. Attach end of clear tubing to bleeder valve nipple
Figure 3-47. Valve Adjustment
and place other end in container to catch oil. Using
a 3/8" wrench, slowly turn bleeder valve counter-
1. The ideal adjustment is 3/8" (9.5 mm). Do not push clockwise to bleed air from cylinder. Have operator
plunger in more than 3/8" (9.5 mm). The extra in platform just crack drive controller in reverse. This
adjustment is needed for turntable bearing play. will activate brake valve sending charge pressure to
lockout cylinder. Close valve when an unbroken,
3.8 OSCILLATING AXLE BLEEDING steady stream of oil is seen.
PROCEDURE AND LOCKOUT TEST 3. Repeat procedure for other lockout cylinder.
Lockout Cylinder Bleeding (Early Cylinders)

NOTE: The following procedure is for machines built in the
USA prior to S/N 0300107512 and machines built in
Belgium prior to S/N 1300003222.
FULLY LOWER PLATFORM AND CENTER BOOM OVER REAR AXLE

BEFORE STARTING BLEEDING PROCEDURE.
ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS

ARE BLOCKED, AND BRAKE WIRE IS DISCONNECTED.
3-64 – JLG Lift – 3121180

Oscillating Axle Lockout Test 15. If lockout cylinders do not function properly, have
qualified personnel correct the malfunction before
any further operation.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, 3.9 SWING BEARING

ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED. Description
NOTE: Ensure boom is fully retracted, lowered, and cen- The swing bearing has five major components: housing,
tered between drive wheels before starting lockout worm, worm gear, output pinion, and gear/pinion cap.
cylinder test.
Servicing of these units requires a press, a 3/8" 12 point
socket, a 1/2" socket, a 3/4" socket, torque wrench (80 ft-
1. Place a 6" (15 cm) high block with ascension ramp
lb), steel hammer, soft face hammer, bearing puller (exter-
in front of left front wheel.
nal and internal), and a large flat blade screw driver. Also
2. From platform control station, activate machine needed are a shim and seal kit (refer to JLG Parts Man-
hydraulic system. ual), 3/4" steel rod at least 10" long, silicone sealant, Mobil
3. Place FUNCTION SPEED CONTROL and DRIVE SHC 007 grease, Mobil SHC 460 grease, Loctite #242 for
SPEED/TORQUE SELECT control switches to LOW bolts, and other parts that may be worn out.
positions.
Removal
4. Place DRIVE control lever to FORWARD position
and carefully drive machine up ascension ramp until Refer to Figure 3-48., Swing Bearing Installation.
left front wheel is on top of block.
1. Attach an adequate support sling to boom and draw
5. Carefully activate SWING control lever and position all slack from sling. Prop or block boom if possible.
boom over right side of machine.
2. Tag and disconnect hydraulic lines (1) running
6. With boom over right side of machine, place DRIVE through center of turntable (2) and frame (3). Use a
control lever to REVERSE and drive machine off of suitable container catch residual hydraulic fluid. Cap
block and ramp. lines and ports.
7. Have an assistant check to see left front wheel 1. Clean area around swing motor (4) to prevent any
remains locked in position off of ground. dirt from entering system.
8. Carefully activate SWING control lever and return 2. Tag and disconnect hydraulic lines running to swing
boom to stowed position (centered between drive motor. Cap or plug all openings.
wheels). When boom reaches center, stowed posi-
3. Attach suitable overhead lifting equipment to base of
tion, lockout cylinders should release and allow
turntable weldment (2).
wheel to rest on ground, it may be necessary acti-
vate DRIVE to release cylinders. 4. Scribe a line on inner race of swing bearing (5) and
underside of turntable to help align bearing during
9. Place 6" (15 cm) high block with ascension ramp in
installation. Remove bolts (6) and washers (7) from
front of right front wheel.
turntable and bearing inner race. Discard bolts.
10. Place DRIVE control lever to FORWARD and care-
5. Use lifting equipment to lift complete turntable
fully drive machine up ascension ramp until right
assembly from bearing. Ensure no damage occurs
front wheel is on top of block.
to turntable, bearing, or frame components. Care-
11. Carefully activate SWING control lever and position fully place turntable on a suitably supported trestle.
boom over left side of machine.
6. Scribe a line on outer race of swing bearing and
12. With boom over left side of machine, place DRIVE frame to help align bearing during installation.
control lever to REVERSE and drive machine off of
7. Remove bolts (8) and washers (9) from outer race of
block and ramp.
bearing to frame. Discard bolts.
13. Have an assistant check to see that right front wheel
8. Use suitable lifting equipment to remove bearing
remains locked in position off ground.
and rotation box assembly from frame. Move to a
14. Carefully activate SWING control lever and return clean, suitably supported work area.
boom to stowed position (centered between drive
wheels). When boom reaches center, stowed posi-
tion, lockout cylinders should release and allow
wheel to rest on ground, it may be necessary acti-
vate DRIVE to release cylinders.
3121180 – JLG Lift – 3-65

TO
Motor Hydraulic REMOTE
2 Lines Not Shown 4
Inner Race
1
Outer Race
Figure 3-48. Swing Bearing Installation
3-66 – JLG Lift – 3121180

Disassembly 5. Lift directly up and remove pinon and gear assembly

(10, 16, 17, 34, 18 - 22) from housing (4).
Refer to Figure 3-49., Swing Bearing Drive.
6. Disassemble pinion and gear assembly using a
1. Clean area around swing motor (1) to prevent any press. Support worm gear (20) on press wIth pinion
dirt from entering system. (10) facing down, allowing room for pinion to be
pressed out of gear. Press pinon out of bearing (22),
2. Tag and disconnect hydraulic lines running to swing
spacer (21), and worm gear (20).
motor. Cap or plug all openings.
7. Remove face seal (18) and O-ring (19) from face of
worm gear (20). Note how seal is assembled.
SECURE WORM GEAR SHAFT SO IT DOES NOT PULL OUT ANY 8. Remove bearing (17) and Nilos Ring (16) from pinion
WHEN REMOVING THE SWING MOTOR. FAILURE TO DO SO (18) with an external bearing puller or press.
COULD DAMAGE WORM GEAR SEALS. 9. Remove motor adapter (33) and shim (34).
3. Remove bolts (2) and washers (3) securing swing 10. Remove two 1/2" bolts (25) from worm cap (26) with
motor to swing drive housing (4). a 3/4" socket. Remove shIms (27) and seal (28) and
discard.
4. Carefully pull swing motor from housing.
11. Remove worm (29) from housing (4) by pushing
Refer to Figure 3-55., Swing Motor Removal and Installation.
worm from motor end using a steel rod and hammer.
1. Remove two 5/16" bolts (5) and washers (6) that Use a soft hammer to tap worm on hex end to
hold turntable bearing (7) to housing (4). remove bearing (36) from opposite end of housing.
2. Remove two #6 machine screws (8) on cover plate 12. Remove bearing (30) from worm (29) using an exter-
(9) immediately in front of pinion (10). nal bearing puller or press.
3. Remove eight 3/8" 12 point cap screws (11) from 13. Remove press fit bearing cup (35) from adapter (33)
gear pinion cap (12). Pry cap from housing. Cover using a small pry bar or by welding a small bead of
plate (9) will come off with cap. Note where sealant weld on internal diameter of the cup.
is on cover and plate so it can be applied in same
location during assembly. Note number and color of
shims (14) between cap and housing.
4. Remove six small screws (15) from cover plate. Pry
cover plate (9) from cap (12). Discard cover plate.
Note number and color of shims (13) between cover
plate and cap.
NOTE: If there are five screws or drive screws holding cover

plate to cap, a new cap (12) should be ordered. This
is an older version; new cover plate has six holes.
3121180 – JLG Lift – 3-67

33
1 34
2 35,36
3 4
5
6
29
30, 32
27
26
25
22, 33
7 21
28
20
19
18
15
8
10
16
17, 34
14
13
12
11
Figure 3-49. Swing Bearing Drive
3-68 – JLG Lift – 3121180

Assembly 14. Place gear cap assembly over pinion assembly and
install shims set aside in step 6.
Refer to Figure 3-49., Swing Bearing Drive.
15. Install eight 3/8" 12 point screws (11) and torque to
1. Press bearing cup (17) in cap (12). 60 ft-lb (81 Nm).
2. Place bearing cup (33) in housing (4). 16. Install 2 small screws (8).
3. Put face seal (18) and O-ring (19) on hub of worm 17. Install seal (28) in worm cap (26) at hex end of worm.
gear (20). 18. Install motor (3) to adapter (33) with two 1/2" bolts (1),
4. Place worm gear (20) on press with face seal up and washers (2), and sealant. Torque to 80 ft-lb (108.5 Nm).
press pinion (10) into worm gear. Place Nilos Ring 19. Install turntable bearing (7) to housing (4) with two 5/16"
(16) on pinion so cup shape is up and press bearing bolts (5) and washers (6).
(34) on pinion tight to Nilos Ring.
20. Fill unit with SHC 007 grease. Grease top bearing
5. Turn assembly over and place spacer (21) on pinion with Mobil SHC 460 grease.
against gear hub so hub of spacer faces up. Press
bearing (22) on pinion and tight to spacer and gear. Installation
6. Place pinion gear assembly in housing. Place gear
Refer to Figure 3-48., Swing Bearing Installation.
cap (12) and shims (14) over gear/pinion assembly
to achieve a slight preload on pinion bearings. 1. Install bearing to rotation box with two capscrews,
Remove cap and shims and set shims aside. Install with fill plug of bearing close to gear as bolt pattern
a new cover plate (9) on cap with six screws (15) allows. Do not tighten capscrews.
and shims (13) equal or close to total thickness of
2. Line up high spot (blue) of bearing with center tooth
shims removed. Apply sealant (Permatex #2) to
of worm gear. Set backlash to 0.008 - 0.010 inch
both sides of each shim and tighten screws, taking
(0.20 - 0.25 mm). Tighten capscrews as shown in
care not to twist screws off. Set assembly aside.
Figure 3-50., Swing Bearing Torque Sequence.
3. Apply Mobiltac 375 Open Gear Compound or equiv-
alent to bearing and worm gear teeth.
ROLLER BEARINGS (3 0,36) AND CUPS (32,35) MUST BE
INSTALLED WITH SMALL ENDS FACING OUT ON EACH SIDE OF 4. Grease bearing. Grease fitting is on inside wall of
MACHINE OR EXCESSIVE PLAY WILL CAUSE BINDING AND DAM- inner race of bearing or on newer bearings remove
AGE TO EQUIPMENT. plugs on both sides of bearing. Reinstall plugs after
greasing.
7. Install bearing (36) with small end facing to outside
of machine on bore end of worm (34). NOTE: If Mobiltac 375 Open Gear Compound is not avail-
able, Multi-Purpose Grease (MPG) can be substi-
8. Install worm (29), hex end first, into housing (4). tuted, however service interval will be shorter.
5. Using suitable lift equipment and install bearing/

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT rotation box assembly to frame with soft spot (red)
WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH- 90 degree relative to load axis. If reusing old bear-
MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL ing, ensure scribed line of outer bearing race aligns
SHOULD BE CHECKED PRIOR TO USE. with scribed mark on frame.
9. Install bearing cup (35) into worm bore of housing.

10. Install motor adapter (33) and 1 shim (34) to bore SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN
end of housing using Install bearing (30) with small FRAME AND TURNTABLE. JLG INDUSTRIES RECOMMENDS ALL
end facing to outside of machine on hex end of REMOVED GRADE 8 BEARING NUTS AND BOLTS BE DISCARDED
worm (29). Place bearing cup (32) over bearing and AND REPLACED WITH NEW NUTS AND BOLTS. IT IS IMPERATIVE
lightly tap cup into bore using a soft hammer. THAT REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.
11. Install worm cap (26) using shims (27) to achieve USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
0.000 to 0.001" end play. Use 3/4" bolts (25) and
sealant. Torque to 80 ft-lb (108.5 Nm). 6. Apply a light coating of Loctite 271 to new bearing
bolts and loosely install bolts and washers through
12. Install pinion/gear assembly in housing so gear
frame and outer bearing race.
teeth mesh with worm gear teeth.
13. Apply silicone sealant to housing surface where cap
assembly touch. This includes vertical surface.
3121180 – JLG Lift – 3-69

Turntable Bearing Mounting Bolt Condition

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT Check
WRENCH IS USED TO TIGHTEN BEARING ATTACHMENT BOLTS,
CHECK TORQUE SETTING ACCURACY OF TOOL BEFORE USE. NOTE: This check is designed to replace existing bearing
bolt torque checks on JLG Lifts in service. This
7. Tighten bolts to an initial torque of 130 ft-lb (176 Nm) check must be performed after first 50 hours of
following torque sequence shown in Figure 3-50., machine operation and every 600 hours of machine
Swing Bearing Torque Sequence. Tighten to a final operation thereafter. Replace missing or loose bolts
torque of 190 ft-lb (257 Nm) following same with new bolts and torque to value specified in
sequence. torque chart after lubricating bolt threads with Loctite
#271. After replacing and re-torquing bolt or bolts,
3 17 recheck all existing bolts for looseness.
7 13
Check Frame To Bearing Bolts
11 9
3
1. Fully retracted boom and elevate to 70 degrees (full
7 21
11 17 elevation).
15 13
15
19 9
5 2. Try and insert a 0.0015" feeler gauge between bolt
23 5
head and hardened washer at positions shown in
Figure 3-51., Swing Bearing Feeler Gauge Check.
2 2 1 1
6 24
20
10
6 16 16
14
18 12
22 4 8
10 12
14 8
18 4
Figure 3-50. Swing Bearing Torque Sequence

.0015" Feeler Gauge
8. Remove lifting equipment from bearing.
9. Use suitable lift equipment to carefully position turn- Figure 3-51. Swing Bearing Feeler Gauge Check
table assembly above machine frame.
3. Ensure 0.0015" feeler gauge will not fit under bolt
10. Carefully lower turntable onto swing bearing. Ensure head to bolt shank.
scribed line of inner race of bearing aligns with
4. Swing turntable 90 degrees, and check some
scribed mark on turntable. If a new swing bearing is
selected bolts at the new position.
used, ensure filler plug fitting is at 90 degrees from
fore and aft centerline of turntable. 5. Continue rotating turntable at 90 degrees intervals
until a sampling of bolts have been checked in all
11. Apply a light coating of Loctite 271 to new bearing
quadrants.
bolts and install through turntable and inner race of
bearing.
12. Tighten bolts to an initial torque of 130 ft-lb (176 Nm)
following torque sequence shown in Figure 3-52.
Tighten to a final torque of 190 ft-lb (257 Nm) follow-
ing same sequence.
13. Remove lift equipment.
14. Route hydraulic lines through center of turntable and
frame. Connect as tagged prior to removal.
15. Following all applicable safety precautions, activate
hydraulic system and functionally check swing sys-
tem for proper and safe operation.
3-70 – JLG Lift – 3121180

Check Turntable To Bearing Bolts Wear Tolerance

1. Fully retract boom and elevate to 70 degrees (full
elevation).Try and insert a 0.0015" feeler gauge TURNTABLE REF.
between bolt head and hardened washer at posi-
tions shown in Figure 3-52., Swing Bearing Feeler
Gauge Check.
MEASURING SWING
POINT BEARING
FRAME REF.
Figure 3-53. Swing Bearing Tolerance Measuring Point
1. Position boom over side of machine with upper

.0015" Feeler Gauge boom horizontal, telescope fully extended, and mid/
lower boom stowed. Measure and record distance
Figure 3-52. Swing Bearing Feeler Gauge Check between swing bearing and turntable using a mag-
netic base dial indicator.
2. Lower boom to horizontal and fully extend boom. 2. At same point, position boom over side of machine
3. Try and insert a 0.0015" feeler gauge between bolt with Upper Boom and Mid/Lower Boom fully ele-
head and hardened washer at position indicated by vated. Measure and record distance between swing
arrow in Figure 3-52., Swing Bearing Feeler Gauge bearing and turntable using a magnetic base dial
Check. indicator.
3. If there is a difference greater than 0.057" (1.40 mm),
replace swing bearing.
4. If there is a difference less than 0.057" (1.40 mm)
and any of the following conditions exist, remove
and inspect bearing.
a. Metal particles in grease.
b. Increased drive power.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble
bearing and return to service.
3121180 – JLG Lift – 3-71

3.10 SWING MOTOR • Before you disassemble motor or any of its compo-
nents read this entire section. It provides important
information on parts and procedures to service motor.
• Before disconnecting and removing motor, thoroughly
IF HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN
clean off all outside dirt, especially from around fittings
EXCESS OF 200°F (93.3°C)], SEALS CAN SHRINK, HARDEN, OR
and hose connections. Remove rust or corrosion from
CRACK AND LOSE THEIR SEALING ABILITY.
coupling shaft.
Preparation Before Disassembly • Remove coupling shaft connections and hose fittings
and immediately plug port holes and fluid lines.
• Remove motor from system, drain fluid, and move it to
PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY a clean work surface.
CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION • Clean and dry motor before disassembly.
OR FIRE COULD CAUSE INJURY OR DEATH.
• Keep parts separate to avoid nicks and burrs.
• Discard all seals and seal rings as they are removed
from motor. Replace all seals, seal rings and any dam-
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA aged or worn parts with OEM approved service parts.
OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.
• As you disassemble motor, clean all parts except seals
in clean petroleum-based solvent, and blow them dry.
NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COM-
PONENTS. DO NOT FORCE OR ABUSE CLOSELY FITTED
PARTS.
Figure 3-54. Swing Motor - Cutaway
3-72 – JLG Lift – 3121180

Table 3-11. Swing Motor Troubleshooting
Trouble Cause Remedy

Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or “O” Rings. Torque to
manufacturers specifications.
2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.
3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing (a) Loosen then tighten single bolt to torque specification.
area deteriorated by corrosion. (b) Replace bolt.
4. Internal shaft seal (16) worn or damaged. Replace seal. Disassembly of motor unit necessary.
5. Worn coupling shaft (12) and internal seal (16). Replace coupling shaft and seal by disassembling unit.
Significant loss of speed under load 1. Lack of sufficient oil supply (a) Check for faulty relief valve and adjust or replace as
required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for temperature of opera-
tion.
2. High internal motor leakage Replace worn rotor set by disassembling unit.
3. Severely worn or damaged internal splines. Replace rotor set, drive link and coupling shaft by disas-
sembling unit.
4. Excessive heat. Locate excessive heat source (usually a restriction) in the

system and correct the condition.
Low mechanical efficiency or undue 1. Line blockage Locate blockage source and repair or replace.
high pressure required to operate unit
2. Internal interference Disassemble unit, identify and remedy cause and repair,
replacing parts as necessary.
3. Lack of pumping pressure Check for and repair worn pump.
4. Excessive binding or loading in system external to Locate source and eliminate cause.
motor unit.
3121180 – JLG Lift – 3-73

Removal • Remove motor, drain fluids, and take it to a clean work

surface.
• Clean and dry motor before disassembly.
1. Thoroughly clean area around swing motor to pre-
• As you disassemble motor, clean all parts except seals
vent dirt from entering system.
in clean petroleum-based solvent and blow them dry.
2. Tag and disconnect hydraulic lines to swing motor.
Cap or plug all openings.
3. Secure worm gear shaft so it does not pull out any PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY
when removing swing motor. Failure to do so could CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLO-
damage worm gear seals. SION OR FIRE COULD CAUSE INJURY OR DEATH.
4. Remove bolts securing swing motor to swing drive
assembly.
5. Carefully pull the swing motor from the swing drive. WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA
OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.
Preparation Before Disassembly
• Read this entire section before you disassemble motor
or any of its components for important information on NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPO-
parts and procedures. NENTS. DO NOT FORCE OR ABUSE CLOSELY FITTED PARTS.
• Thoroughly clean off outside dirt, especially around fit-
tings and hose connections, before disconnecting and • Keep parts separate to avoid nicks and burrs.
removing motor. Remove rust or corrosion from cou- • Discard seals and seal rings as they are removed from
pling shaft. motor. Replace all seals, seal rings and any damaged
• Remove coupling shaft connections and hose fittings or worn parts with OEM approved service parts.
and immediately plug port holes and fluid lines.
NOTE: Secure this end of

shaft when removing swing
motor. If it starts to pull out
with the swing motor, it can
damage internal seals.
Torque swing motor mounting
Swing Motor bolts to 85 ft-lb (115 Nm).
Figure 3-55. Swing Motor Removal and Installation
3-74 – JLG Lift – 3121180

Disassembly and Inspection

Refer to Figure 3-56., Swing Motor - Exploded View.
1. Place motor in a soft jawed vice, with coupling shaft
(12) pointed down and vise jaws clamping firmly on
sides of housing (18) mounting flange, or port
bosses. Remove manifold port O-rings if applicable.
3. Remove special ring head bolts (1) with 1/2" or 9/16"

socket. Inspect bolts for damaged threads or sealing
rings. Replace damaged bolts.
IF MOTOR IS NOT HELD FIRMLY IN VISE, IT COULD DISLODGE

DURING SERVICE PROCEDURES AND CAUSE INJURY.
2. Scribe an alignment mark down and across motor

components from end cover (2) to housing (18) to
facilitate reassembly orientation where required.
4. Remove end cover assembly (2) and seal ring (4).

Discard seal ring.
5. Thoroughly wash end cover (2) in proper solvent

and blow dry. Be sure end cover valve apertures are
3121180 – JLG Lift – 3-75

free of contamination. Inspect end cover for cracks .

and bolt head recesses for good bolt head sealing
surfaces. Replace end cover as necessary.
NOTE: A polished pattern (not scratches) on the cover from

rotation of commutator (5) is normal. Discoloration
would indicate excess fluid temperature, thermal
shock, or excess speed and require system investi-
gation for cause and close inspection of end cover,
commutator, manifold, and rotor set.
6. Remove commutator ring (6) and inspect for cracks

or burrs.
1. Remove manifold (7). Inspect for cracks, surface scor-

ing, brinelling, or spalling and replace if any of these con-
ditions exist. A polished pattern on the ground surface
from commutator or rotor rotation is normal. Remove
and discard seal rings (4) on both sides of manifold.
7. Remove commutator (5) and seal ring (3). Remove

seal ring from commutator. Use an air hose to blow
air into ring groove until seal ring lifts out. Discard
seal ring. Inspect commutator for cracks or burrs,
wear, scoring, spalling, or brinelling. Replace com-
mutator and commutator ring as a matched set If
any of these conditions exist.
NOTE: Manifold consists of plates bonded together and

cannot be disassembled. Compare both sides of
manifold to ensure same surface is reassembled
against rotor set.
3-76 – JLG Lift – 3121180

2. Remove rotor set (8) and wearplate (9), together to NOTE: A polished pattern on wear plate from rotor rotation
retain rotor set in its assembled form, maintaining is normal.Place rotor set (8) and wear plate (9) on a
same rotor vane to stator contact surfaces. Drive link flat surface and center rotor in stator so two rotor
(10) may come away from coupling shaft (12) with lobes (180 degrees apart) and a roller vane center-
rotor set, and wearplate. You may have to shift the line are on the same stator centerline. Check rotor
rotor set on the wearplate to work drive link out of lobe to roller vane clearance with a feeler gage at
rotor and wearplate. Inspect rotor set in its assem- this common centerline. If there is more than 0.005"
bled form for nicks, scoring, or spalling on any sur- (0.13 mm) of clearance, replace rotor set.
face and for broken or worn splines. If rotor set
component requires replacement, complete rotor
set must be replaced as it is a matched set. Inspect
wearplate for cracks, brinelling, or scoring.
3. Discard seal ring (4) between rotor set and wearplate.
NOTE: If rotor set (8) has two stator halves and two sets of
seven vanes as shown, check rotor lobe to roller
vane clearance at both ends of rotor.
4. Remove drive link (10) from coupling shaft (12) if it

was not removed with rotor set and wear plate.
Inspect drive link for cracks and worn or damaged
splines. No perceptible lash (play) should be noted
between mating spline parts. Remove seal ring (4)
from housing (18) and discard.
NOTE: Rotor set (8) components may become disassem-

bled during service. Mark surface of rotor and stator
facing UP, with etching ink or grease pencil before
removal to ensure correct reassembly of rotor into
stator and rotor set into motor. Mark all rotor compo-
nents and mating spline components for exact repo-
sitioning at assembly for maximum wear life and
performance of rotor set and motor.
3121180 – JLG Lift – 3-77

5. Remove thrust bearing (11) from top of coupling

shaft (12). Inspect for wear, brinelling, corrosion, and
missing rollers.
6. Check exposed portion of coupling shaft (12) for

signs of rust and corrosion which might prevent its
withdrawal through seal and bearing. Use crocus
cloth or fine emery paper as needed.
NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020" (0.51 mm) diametrically, replace
coupling shaft. A slight “polish” is permissible in
shaft bearing areas. Anything more requires cou-
pling shaft replacement.
7. Remove coupling shaft (12), by pushing on output 1. Remove and discard seal ring (4) from housing (18).
end of shaft. Inspect coupling shaft bearing and seal
surfaces for spalling, nicks, grooves, severe wear or
corrosion and discoloration. Inspect for damaged or
worn internal and external splines or keyway.
Replace shaft if any of these conditions exist.
3-78 – JLG Lift – 3121180

2. Remove thrust bearing (15) and thrust washer (14). 5. Inspect housing (18) assembly for cracks, machined
Inspect for wear, brinelling, corrosion and a full com- surfaces for nicks, burrs, brinelling, or corrosion.
plement of retained rollers. Remove burrs that can be removed without chang-
ing dimensional characteristics. Inspect tapped
holes for thread damage. If housing is defective in
these areas, discard housing assembly.
3. Remove seal (16) and back up ring (17) from hous-

ing (18) and backup washer (25). Discard both.
6. If housing (18) assembly has passed inspection to
this point, inspect housing bearings/bushings (19)
and (13) if they are captured in housing cavity. Two
thrust washers (14) and thrust bearing (15) bearing
rollers must be firmly retained in bearing cages, but
must rotate and orbit freely. All rollers and thrust
washers must be free of brinelling and corrosion.
Bushing (19) or (13) to coupling shaft diameter clear-
ance must not exceed 0.010 inch (0.025 mm). A bear-
ing, bushing, or thrust washer that does not pass
inspection must be replaced. If housing has passed
this inspection, disassembly of motor is complete.
4. Remove housing (18) from vise. Invert housing and

remove seal (20) with a blind hole bearing or seal
puller. Discard seal.
3121180 – JLG Lift – 3-79

7. Measure and note depth or location of bearing/bush- 8. Use a suitable size bearing puller to remove bearing/
ing (13) in relation to housing wear plate surface, and bushings (19) and (13) from housing (18) If Bearings,
depth or location of bearing/bushing (19) in relation bushing or thrust washers must be replaced without
to beginning of bearing/bushing counter bore before damaging housing. Remove thrust washers (14) and
removing bearings/bushings. This ensures correct thrust bearing (15) if previously retained in housing by
reassembly of new bearings/bushings. bearing (13).
3-80 – JLG Lift – 3121180

20
18
8
25
8C 17
16
8E 14
15 19
14
8B
13
4 12
8A
4
8D
10
9
4
8
4
7
5
4
6
3
4
2
1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used
2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used
3. Seal Ring 8. Rotor Set 9. Wear Plate 14. Thrust Washer 19. Outer Bushing 24. Not Used
4. Seal Ring 8A. Rotor 10. Drive Link 15. Thrust Bearing 20. Dirt & Water Seal 25. Backup Washer
5. Commutator 8B. Stator Half 11. Thrust Bearing 16. Seal 21. Not Used
Figure 3-56. Swing Motor - Exploded View
3121180 – JLG Lift – 3-81

Assembly NOTE: If A bearing mandrel is not available and alternate

methods are used to press in bearing/bushing (13)
Refer to Figure 3-56., Swing Motor - Exploded View. and (19). bearing/bushing depths specified must be
achieved to Ensure adequate bearing support and
Replace seals and seal rings with new ones each time
correct relationship to adjacent components when
motor unit is reassembled. Lubricate seals and seal rings
assembled.
with SAE 10W40 oil or clean grease before assembly.
NOTE: Do not oil or grease parts before assembly unless

otherwise indicated.
SOLVENTS ARE FLAMMABLE. EVEN A SMALL EXPLOSION OR

FIRE CAN CAUSE INJURY OR DEATH. BE EXTREMELY CAREFUL
WHEN USING ANY SOLVENT.
Wash all parts in clean petroleum-based solvents before

assembly. Blow dry with compressed air. Remove any
paint chips from end cover mating surfaces, commutator
set, manifold rotor set, wear plate and housing, and from
port and sealing areas.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA

OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO
1. If housing (18) bearing components were removed HOUSING AND MUST BE DISCARDED WHEN REMOVED.
for replacement, thoroughly coat and pack a new
2. Inner housing bearing/bushing (13) can now be
outer bearing/bushing (19) with clean corrosion
pressed into its counter-bore in housing (18) flush to
resistant grease recommended in material section.
0.03 inch (0.76 mm) below housing wear plate con-
Press new bearing/bushing into counterbore at
tact face. Use opposite end of bearing mandrel used
mounting flange end of housing, using appropriately
to press in outer bearing/bushing (19).
sized bearing mandrel as described to control bear-
ing/ bushing depth. Housing requires use of bearing
mandrel to press bearing/ bushing (19) into housing
to a required depth of 0.151/0.161" (3.84/4.09 mm)
from end of bearing counterbore.
NOTE: Bearing mandrel must be pressed against lettered

end of bearing shell. Housing bore must be square
with press base and bearing/bushing not cocked
when pressing a bearing/bushing into housing.
3-82 – JLG Lift – 3121180

3. Press new dirt and water seal (20) into housing (18) 6. Install thrust washer (14) and thrust bearing (15).
outer bearing counterbore. Press in dirt and water
seal (20) until flange is flush against housing.
NOTE: Motor requires one thrust washer (14) with thrust

bearing (15). Coupling shaft is seated directly
4. Place housing (18) assembly into a soft jawed vise
against thrust bearing.
with coupling shaft bore down, clamping against
mounting flange.
7. Apply masking tape around splines or keyway on
shaft (12) to prevent damage to seal.
5. Assemble a new backup ring (17), new backup

washer (25), and new seal (16) with seal lip facing
toward inside of motor, into their counterbores in
housing (18).
3121180 – JLG Lift – 3-83

8. Apply a generous amount of clean, corrosion resis- 9. Apply a small amount of clean grease to a new seal
tant grease to lower (outer) housing bearing/bush- ring (4) and insert it in housing (18) seal ring groove.
ing (19). Install coupling shaft (12) into housing (18),
seating it against thrust bearing (15).
NOTE: One or two alignment studs screwed finger tight into

housing (18) bolt holes, approximately 180 degrees
apart, will facilitate assembly and alignment of com-
ponents required in the following procedures. Studs
O U T E R B E A R I NG ( 1 9 ) I S N O T L U B R I C A T E D B Y S Y S T E M can be made by cutting off heads of 3/8-24 UNF 2A
HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH or 5/16-24 UNF 2A bolts as required that are over 0.5
RECOMMENDED GREASE. inch (12.7 mm) longer than bolts (1) used in motor.
NOTE: Coupling shaft (12) will be flush or just below hous- 10. Install drive link (10), long splined end down, in cou-
ing wear surface when properly seated with coupling pling shaft (12) and engage drive link splines in
shaft (12). Coupling shaft must rotate smoothly on mesh with coupling shaft splines.
thrust bearing package.
NOTE: Use alignment marks on coupling shaft and drive link

before disassembly to assemble drive link splines in
their original position in mating coupling shaft
splines.
3-84 – JLG Lift – 3121180

11. Assemble wear plate (9) over drive link (10) and 13. Place assembled rotor set (8) on wear plate (9) with
alignment studs onto housing (18). rotor counterbore and seal ring side down and
splines into mesh with drive link splines.
12. Apply a small amount of clean grease to a new seal

ring (4) and assemble it into seal ring groove on NOTE: It may be necessary to turn one alignment stud out of
wear plate side of rotor set stator. housing (18) temporarily to assemble rotor set (8) or
manifold (7) over drive link.
NOTE: Rotor set rotor counterbore side must be down

against wear plate for drive link clearance and to
maintain original rotor-drive link spline contact. A
rotor set without a counterbore that was not etched
before disassembly can be reinstalled using drive
link spline pattern on rotor splines if apparent, to
determine which side was down. Rotor set seal ring
groove faces toward wear plate (9).
14. Apply clean grease to a new seal ring (4) and

assemble it in seal ring groove in rotor set contact
side of manifold (7).
NOTE: If rotor set is disassembled and cannot be easily

reassembled, go to One Piece Stator Assembly,
page 3-88 or Two Piece Stator Assembly, page 3-89.
NOTE: Manifold (7) is made of several permanently bonded

plates. Manifold surface that contacts rotor set has a
series of irregular shaped cavities on largest circum-
ference or circle around inside diameter. Polished
impression left on manifold by rotor set is another
indication of which surface must contact rotor set.
3121180 – JLG Lift – 3-85

15. Place manifold (7) over alignment studs and drive 18. Install new seal ring (3) flat side up, into commutator (5).
link (10) and onto rotor set. Be sure correct manifold Assemble commutator over end of drive link (10) on
surface is against rotor set. manifold (7) with seal ring side up.
16. Apply grease to new seal ring (4) and insert it in

manifold seal ring groove.
19. Install new seal ring (4) in end cover (2) and install
end cover over alignment studs and on commutator
17. Install commutator ring (6) over alignment studs on
set. If end cover has only 5 bolt holes be sure cover
manifold.
holes are aligned with 5 threaded holes in housing
(18). Correct 5 bolt end cover bolt hole relationship
to housing port bosses is shown:
3-86 – JLG Lift – 3121180

20. Assemble bolts (1) and screw in finger tight. Remove

and replace two alignment studs with bolts after other
bolts are in place. Alternately and progressively
tighten bolts to pull end cover and other components
into place with a final torque of 25-30 ft-lb (34-41 Nm).
NOTE: If end cover has a valve (24) or five bolt holes, use
line scribed on cover to radially align end cover to its
original position.
3121180 – JLG Lift – 3-87

One Piece Stator Assembly 4. Assemble six vanes, or as many vanes that readily
assemble in stator vane pockets.
A disassembled rotor stator and vanes that cannot be
readily assembled by hand can be assembled using the
following procedures:
1. Place stator on wear plate (9) with seal ring (4) side
down, after following assembly procedures 1
through 13. Be sure seal ring is in place.
EXCESSIVE FORCE USED TO PUSH ROTOR VANES IN PLACE

COULD SHEAR OFF COATING APPLIED TO STATOR VANE
POCKETS.
5. Grasp output end of coupling shaft (12) with locking

2. If assembly alignment studs are not used, align sta- pliers or other appropriate turning device and rotate
tor bolt holes with wear plate and housing bolt coupling shaft, drive link and rotor to seat rotor and
holes. Turn two bolts (1) finger tight in bolt holes assembled vanes into stator, creating the necessary
approximately 180 degrees apart to retain stator and clearance to assemble the seventh or full comple-
wear plate stationary. ment of seven vanes. Assemble the seven vanes
3. Assemble rotor, counterbore down if applicable, into using minimum force.
stator, and onto wear plate (9) with rotor splines into
mesh with drive link (10) splines.
Remove two bolts (1) if used to retain stator and wear plate.
Go to Step 14 on page 3-85 to continue assembly.
3-88 – JLG Lift – 3121180

Two Piece Stator Assembly 9. Grasp output end of coupling shaft (12)
with locking pliers or other appropriate turning
A disassembled rotor set (8) that cannot be easily by hand device and rotate coupling shaft, drive link, and rotor
and has a two piece stator, can be assembled using the to seat rotor and assembled vanes into stator, creat-
following procedures: ing necessary clearance to assemble seventh or full
complement of seven vanes. Assemble seven vanes
1. Place stator half on wear plate (9) with seal ring (4)
using minimum force.
side down, after following motor assembly proce-
dures 1 through 13. Be sure seal ring is in place. Go to Step 14 on page 3-85 to continue assembly.
2. Align stator bolt holes with wear plate and
housing bolts. Turn two alignment studs
Final Checks
finger tight into bolt holes approximately 180 degrees 1. Pressurize motor with 100 psi dry air or nitrogen and
apart to keep stator half and wear plate stationary. submerge in solvent to check for external leaks.
3. Assemble rotor, counterbore down if applicable, into 2. Check motor for rotation. Torque required to rotate cou-
stator half, and onto wear plate (9) with rotor splines pling shaft should not be more than 50 ft-lb (68 Nm).
into mesh with drive link (10) splines.
3. Pressure port with “A” cast under it on housing (18)
NOTE: Use marking applied to rotor set components to is for clockwise coupling shaft rotation as viewed
reassemble components in their original relationship from the output end of coupling shaft. Pressure port
to ensure ultimate wear life and performance. with “B” cast under it is for counter clockwise cou-
pling shaft rotation.
4. Assemble six vanes, or as many vanes that readily 4. Use test stand and check motor operation.
assemble into stator vane pockets.
Installation
EXCESSIVE FORCE USED TO PUSH ROTOR VANES IN PLACE
COULD SHEAR OFF COATING APPLIED TO STATOR VANE 1. Carefully insert swing motor into swing drive, mak-
POCKETS. ing sure swing motor shaft key is aligned correctly.
5. Grasp output end of coupling shaft (12) 2. Secure swing motor to swing drive assembly with
with locking pliers or other appropriate turning two bolts and flat washers. Apply threadlocker JLG
device and rotate coupling shaft, drive link and rotor P/N 0100019 to threads of retaining bolts and torque
to seat rotor and assembled vanes (8C) into stator to 85 ft-lb (115 Nm).
half, creating necessary clearance to assemble sev-
enth or full complement of seven vanes. Assemble
the seven vanes using minimum force. TORQUE
6. Place second stator half on a flat surface with seal
ring groove up. Apply a small amount of grease to a
new seal ring (4) and install it in stator half ring
groove.
7. Assemble second stator half over two alignment
studs and rotor with seal ring side down onto the
first stator half aligning any timing marks applied for 3. Connect hydraulic lines running to swing motor as
this purpose. tagged during removal.
IF STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS)

THAN STATOR HALF (8D) STATOR VANES (8C) OR (8E)OF THE
SAME LENGTH (HEIGHT) AS STATOR HALF MUST BE REASSEM-
BLED IN THEIR RESPECTIVE STATOR HALF FOR ROTOR SET TO
FUNCTION PROPERLY.
8. Assemble six vanes, or as many vanes that readily

assemble into stator vane pockets.
3121180 – JLG Lift – 3-89

3.11 SEMI-TRACK Normal Wear

The semi-track option is available in soft or hard tracks It is normal for the bushing to wear down to the bolt and
and provides increased traction in rough terrain. for the link hole to wear oblong until it is ready to break out
the end.
Testing
Adjustment
With both sides installed, drive machine slowly in both
directions to check track does not catch or hit any part of
machine. Test machine until it can be driven at top speed
and on side slopes without tracks hitting. Check track fre- IMPROPER SLACK ADJUSTMENT CAN CAUSE TRACK PARTS TO
quently first few days after use that all bolts are tight and BREAK.
no damage is being caused to tires or machine.
Place a straight edge long enough to reach from idler to
Removing drive wheel on the tracks. Measure maximum amount of
track sag from high point of track segment to bottom of
If tracks are muddy, wash or drive machine through water straight edge. Properly adjusted track will have 1 to 2
before removing. If tracks will be stored in the laid out inches (25 to 50 mm) slack. (See Figure 3-57.)
position just as they come off machine, move machine to
storage area to remove tracks. If tracks are going to be To adjust the slack measurement, move bolts from first
rolled up and put on a pallet, it is best to remove them on hole to the second to create less slack, or from to second
a hard surface. Remove bolts that hold track together. to the first to create more slack.
These bolts are accessible over the front tires. After nuts
are removed, pound them flush with pad. Drive machine
ahead until bolts are at the bottom between tires. Remove
inside bolts by turning them out with a wrench and punch
out the outside bolts. Drive machine ahead and take off
tracks. If track is to be rolled up, set track on edge and roll
it. Secure end of track and put loose hardware in end of
track.
Table 3-12.Adjustment Chart

Move 1 Hole 2 Holes 3 Holes 4 Holes 5 Holes 6 Holes 7 Holes 8 Holes 9 Holes 10 Holes 11 Holes 12 Holes
Equals 0.81 in 1.62 in 2.43 in 3.25 in 4.06 in 4.87 in 5.68 in 6.50 in 7.31 in 8.12 in 8.93 in 9.75 in
(20.5 mm) (41 mm) (62 mm) (82.5 mm) (103 mm) (124 mm) (144 mm) (165 mm) (186 mm) (206 mm) (227 mm) (248 mm)
3-90 – JLG Lift – 3121180

Figure 3-57. Track Adjustment and Installation
3121180 – JLG Lift – 3-91

A E
Figure 3-58. Auxiliary Pump - Sheet 1 of 2
3-92 – JLG Lift – 3121180

1. Motor 11. Seat 21. O-ring

2. Adapter 12. Needle Bearing 22. Gear Housing
3. Setscrew 13. Washer 23. I.D. Label
4. Mounting Gasket 14. Screw 24. Gasket
5. Coupling 15. Retaining Ring 25. Gear Housing
6. Shaft Seal 16. Gear 26. Beta Plug
7. Stator 17. Idler Shaft 27. Screw
8. Cap Assembly 18. Drive Pin 28. Drive Shaft
9. Spring 19. Dowel Pin 29. Plastic Plug
10. Ball 20. Gasket 30. Plastic Plug
A. Torque 96 to 120 inch-pounds (11 to 13.5 Nm)
B. Torque to 84 inch-pounds (9.5 Nm)
C. Torque 144 to 180 inch-pounds (16 to 20 Nm)
D. Torque 180 to 216 inch-pounds (16 to 24 Nm)
E. Torque 114 to 150 inch-pounds (12 to 17 Nm)
Figure 3-59. Auxiliary Pump - Sheet 2 of 2
3121180 – JLG Lift – 3-93

3.12 GENERATOR Overload Protection

Every 250 hours
Check drive belt for proper tension every 250 hours of STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT
operation. BREAKER.
The circuit breaker protects generator windings from over-

load. If circuit breaker opens, generator output stops. If
circuit breaker continues to open, check for faulty equip-
ment connected to platform receptacles.
1/2 in.
(13 mm)
CIRCUIT
Every 500 hours

BREAKER
Service generator brushes and slip rings every 500 hours

of operation. Hostile environments may require more fre-
quent service.
Brushes and Slip Rings

Refer to Figure 3-60., Inspecting Generator Brushes,
Replacing Brushes, and Cleaning Slip Rings.
INSPECTING BRUSH POSITION

Blow out inside of generator with compressed air every Inspect brush alignment with slip rings. View alignment
500 hours of service. Clean monthly If operating in a hos- through air vents in stator barrel. Brushes must ride com-
tile environment. pletely on slip rings.
INSPECTING BRUSHES
Remove end panel. Inspect wires. Remove brush holder
assembly. Pull brushes from holders.
Replace brushes if damaged, or at or near minimum

length.
CLEANING SLIP RINGS

Visually inspect slip rings. Rings turn dark brown under
normal use. If slip rings are corroded or their surface is
uneven, remove belt to turn shaft by hand for cleaning.
Clean rings with 220 grit emery paper. Remove as little

material as possible. If rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall belt, brush holder assembly, and end panel.
3-94 – JLG Lift – 3121180

Brush Position On Slip Rings
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-60. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3121180 – JLG Lift – 3-95

3.13 FORD EFI ENGINE • Inspect ECM grounds for cleanliness, tightness, and
proper location.
Performing Diagnostics • Inspect fuel system for adequate fuel level, and fuel
quality (concerns such as proper octane, contamina-
1. Verify complaint and determine if it is a deviation tion, winter/summer blend).
from normal operation.
• Inspect intake air system and air filter for restrictions.
2. Once complaint is verified, preliminary checks can
be done. Conduct a thorough visual inspection, be • Inspect battery condition and starter current draw.
alert for unusual sounds or odors, and gather diag- If no evidence of a problem is found after visual/physical
nostic trouble code information. engine check has been performed, proceed to MIL DTC
3. Perform a system check to verify proper system retrieval procedure.
operation. Check for recent information updates.
4. If a diagnostic trouble code (DTC) is stored, contact EFI Diagnostics
a JLG distributor to make an effective repair. EFI diagnostics are designed to assist in locating a faulty
5. If no DTC is stored, select symptom from symptom circuit or component. When a malfunction is detected by
tables and follow diagnostic path or suggestions to the Engine Control Module (ECM), a diagnostic trouble
complete repair. code (DTC) is set and is displayed on the JLG Control
System Analyzer. Refer to Section 6 - JLG Control System
6. After repair has been made and validated for proper
operation, temporarily reinstall the old part to verify it
CLEARING TROUBLE CODES
was the problem source.
To clear ECM trouble codes, disconnect negative terminal
If no matching symptom is available, analyze the com- from battery for approximately 15 minutes.
plaint and develop a plan for diagnostics using wiring dia-
grams, technical assistance, and repair history. ECM and Sensors
Intermittent conditions may be resolved by using a check
sheet to pinpoint the circuit or electrical system compo- CRANKSHAFT POSITION (CKP) SENSOR
nent. Some diagnostic charts contain Diagnostic Aids The crankshaft position (CKP) sensor provides a signal
which give additional information about a system. Be sure used by the engine control module (ECM) to calculate the
to use all of the information that is available to you. ignition sequence and reference pulses which the ECM
uses to calculate RPM and crankshaft position.
VISUAL/PHYSICAL ENGINE INSPECTION
CHECK CAMSHAFT POSITION (CMP) SENSOR AND
Perform a careful visual and physical engine inspection SIGNAL
before performing any diagnostic procedure. Perform all The cams haft posi tion
necessary repairs before proceeding with additional diag- (CM P) se nsor send s a
nosis, this can often lead to repairing a problem without CMP signal to the ECM.
performing unnecessary steps. Use the following guide- The ECM uses this signal
lines when performing a visual/physical inspection check: as a “sync pulse” to trig-
ger injectors in the proper
• Inspect engine for modifications or aftermarket equip- sequence. The ECM uses
ment that can contribute to the symptom. Verify electri- the CMP signal to indicate
cal and mechanical loads or accessory equipment is position of the #1 piston
“OFF” or disconnected before performing diagnosis. during its power stroke.
• Inspect engine fluids for correct levels and leaks. The CMP uses a Hall
Effect sensor to measure
• Inspect vacuum hoses for damage, leaks, cracks,
piston position. This
kinks and improper routing, inspect intake manifold
allows the ECM to calcu-
sealing surface for a possible vacuum leak.
late true sequential fuel injection (SFI) mode of operation.
• Inspect PCV valve for proper installation and operation. If the ECM detects an incorrect CMP signal when engine
is running, DTC 53 will set. If CMP signal is lost when
• Inspect all wires and harnesses for proper connections
engine is running, the fuel injection system shifts to a cal-
and routing; bent or broken connector pins; burned,
culated sequential fuel injection mode based on the last
chafed, or pinched wires; and corrosion. Verify harness
fuel injection pulse, and the engine continues to nun. As
grounds are clean and tight.
long as the fault is present, the engine can be restarted. It
• Inspect engine control module (ECM), sensors, and will run in the previously established injection sequence.
actuators for physical damage.
3-96 – JLG Lift – 3121180

Table 3-13. ECM Diagnostic Trouble Codes
Diagnostic
Trouble Description
Code
0,11 All Systems OK
12 Throttle Position (TP) Sensor Low Voltage
13 Hand Throttle Low Voltage
14 Manifold Absolute Pressure (MAP) Low Voltage
15 Manifold Surface Temperature (MST) Low Voltage
21 Overspeed
22 Throttle Position (TP) Sensor High Voltage
23 Hand Throttle High Voltage
24 Manifold Absolute Pressure (MAP) High Voltage
25 Manifold Surface Temperature (MST) High Voltage
26 Initial Throttle Position Sensor (TPS) High Voltage
31 Fuel Pump Low Voltage
32 Heated Oxygen Sensor (HEGO1) Low Voltage
33 Engine Coolant Temperature (ECT) Sensor High Voltage
34 Heated Oxygen Sensor (HEGO2) Low Voltage
35 Intake Air Temperature (IAT) Sensor High Voltage
36 Heated Oxygen Sensor (HEGO1) Inactive
41 Fuel Pump High Voltage
42 Heated Oxygen Sensor (HEGO1) High Voltage
43 Engine Coolant Temperature (ECT/CHT) Sensor Low Voltage
44 Heated Oxygen Sensor (HEGO2) High Voltage
45 Intake Air Temperature (IAT) Sensor Low Voltage
46 Heated Oxygen Sensor (HEGO2) inactive
51 Low Oil Pressure
52 Crankshaft Position (CKP) Sensor Extra/Missing Pulses
53 Camshaft Position Sensor (CMP) Sensor Illegal Pattern
54 Engine Control Module (ECM) Fault Illegal Operation
55 Engine Control Module (ECM) Fault Illegal Interruption
56 Engine Control Module (ECM) Fault COP (Computer Operating Properly) Failure
57 Engine Control Module (ECM) communications error
61 System Voltage Low
62 System Voltage High
63 Rev Limit Exceeded
64 Adaptive fuel coefficient saturated
NOTE: Critical Codes are numbered in bold and underlined.
3121180 – JLG Lift – 3-97

ENGINE COOLANT TEMPERATURE (ECT) SENSOR HEATED OXYGEN SENSOR

The Engine Coolant Temperature (ECT) sensor is a therm- The heated oxygen sensor is mounted in the exhaust
istor (a resistor which changes value based on tempera- stream to monitor exhaust gas oxygen content. Oxygen in
ture) mounted in the engine coolant stream. Low coolant the exhaust gas reacts with the sensor to produce a volt-
temperature produces a high resistance of 100,000 ohms age output. This voltage should constantly fluctuate from
at -40°C (-40°F). High temperature causes a low resis- approximately 100 mV to 900 mV. Heated oxygen sensor
tance of 70 ohms at 130°C (266°F). The ECM supplies a voltage can be monitored on an IBM PC-compatible com-
5-volt signal to the ECT sensor through resistors in the puter with diagnostic software. By monitoring oxygen sen-
ECM and measures the voltage. The signal voltage will be sor voltage output, the ECM calculates the pulse width
high when the engine is cold and low when the engine is command for injectors to produce proper combustion
hot. By measuring the voltage, the ECM calculates the chamber mixture.
engine coolant temperature. Engine coolant temperature
affects most of the systems that the ECM controls. Low HO2S voltage indicates a lean mixture which results
in a rich command to compensate.
After engine start-up, temperature should rise steadily to
High HO2S voltage indicates a rich mixture which results
about 85°C (185°F), then stabilize when the thermostat
in a lean command to compensate.
opens. If engine has not been run for several hours (over-
night), engine coolant temperature and intake air tempera-
A constant voltage below 200 mV for 10 consecutive sec-
ture displays should be close to each other. A fault in the
onds sets OTC 32. A constant voltage above 650 mV for
engine coolant sensor circuit sets DTC 33 or DTC 43.
10 consecutive seconds sets OTC 42.
ELECTRICALLY ERASABLE PROGRAMMABLE

READ ONLY MEMORY (EEPROM)
The Electrically Erasable Programmable Read Only Mem-
ory (EEPROM) is a permanent memory chip located within
the ECM. The EEPROM contains program and calibration
information needed to control engine operations. If
replaced, the new ECM must be programmed. An IBM-
compatible computer and software containing the correct
program and calibration for the application are required to
program the ECM.
3-98 – JLG Lift – 3121180

Figure 3-61. EFI Component Location
3121180 – JLG Lift – 3-99

Intake Air Temperature (IAT) Sensor Engine Control Module (ECM)

The intake air temperature (IAT) The ECM controls the following:
sensor is a thermistor which
• Fuel metering system
changes resistance based on
temperature of air entering the • Ignition timing
engine. Low temperature pro-
• On-board diagnostics for engine functions
duces a high resistance of
100,000 ohms at -40°C (-40°F). The ECM constantly monitors information from various
High temperature causes a low sensors and controls systems that affect engine perfor-
resistance of 70 ohms at 130°C mance. The ECM performs system diagnostics. It can rec-
(266°F). The ECM supplies a 5- ognize operational problems, alert operator through
volt signal to the sensor and Malfunction Indicator Lamp (MIL), and store diagnostic
monitors signal voltage. Signal trouble codes (DTCs). DTCs identify problem areas to aid
voltage is high when incoming air in making repairs.
is cold and low when incoming
The ECM supplies 5 or 12 volts to power various sensors
air is hot. The ECM calculates
or switches. Power is supplied through resistances in the
incoming air temperature by measuring voltage. The IAT
ECM which are so high in value a test light will not light
sensor signal adjusts spark timing according to incoming
when connected to the circuit. In some cases, even an
air density. An IBM PC-compatible computer with diagnos-
ordinary shop voltmeter will not give an accurate reading
tic software can display air temperature entering the
because its resistance is too low. Therefore, a digital volt-
engine. Temperature should read close to ambient air tem-
meter with at least 10 meg ohms input impedance is
perature when engine is cold, and rise as engine compart-
required to ensure accurate voltage readings. The ECM
ment temperature increases. If engine has not been run for
controls output circuits such as fuel injectors, electronic
several hours (overnight), IAT sensor temperature and
governor, etc., by controlling ground or power feed cir-
engine coolant temperature should read close to each
cuits through transistors or other solid state devices.
other. An IAT sensor circuit failure sets DTC 35 or DTC 45.
The ECM is designed to maintain exhaust emission levels
Manifold Absolute Pressure (MAP) Sensor to government mandated standards while providing excel-
lent operation and fuel efficiency. The ECM monitors
The Manifold Absolute Pressure (MAP) sensor responds numerous engine functions via electronic sensors such as
to changes in intake manifold pressure (vacuum). MAP the throttle position (TP) sensor and heated oxygen sen-
sensor signal voltage to ECM varies from below 2 volts at sor (HO2S).
idle (high vacuum) to above 4 volts with ignition ON,
engine not running, or at wide-open throttle (low vacuum).
The MAP sensor determines:
• Engine vacuum level for engine control purposes.
• Barometric pressure (BARO)
If the ECM detects a voltage significantly lower than the
estimated MAP value for 2 or more consecutive seconds,
DTC 14 will be set. A signal voltage significantly higher
than the estimated MAP value for 2 or more consecutive
seconds will set DTC 24.
3-100 – JLG Lift – 3121180

ECM Inputs/Outputs Throttle Position (TP) Sensor

Inputs—Operating Conditions The throttle position (TP) sensor is a potentiometer con-
nected to the throttle shaft on the throttle body, which is
• Engine Coolant Temperature
built into the electronic governor. The ECM monitors sig-
• Crankshaft Position nal line voltage and calculates throttle position. The TP
sensor signal changes as the throttle valve angle is
• Exhaust Oxygen Content
changed, At a closed throttle position, TP sensor output is
• Manifold Absolute Pressure low. As the throttle valve opens, output increases so that
• Battery Voltage at wide open throttle (WOT), output voltage should be
above 4 volts.
• Throttle Position
• Fuel Pump Voltage The ECM calculates fuel delivery based on throttle valve
angle (operator demand). A broken or loose TP sensor
• Intake Air Temperature may cause intermittent bursts of fuel from an injector and
• Camshaft Position unstable idle because the ECM thinks the throttle is mov-
ing. A hard failure in the TP sensor 5-Volt reference or sig-
Outputs - System Controlled nal circuits for greater than 2 consecutive seconds will set
• Fuel Control either a DTC 12 or DTC 22. A hard failure with the TP sen-
sor ground circuit for more than two consecutive seconds
• Idle Air Control may set DTC 22. If DTC 12 or DTC 22 are set, the throttle
• Electric Fuel Pump is forced to a 6% (idle) position.
• Diagnostics:
- Malfunction Indicator Lamp
- Data Link Connector (DLC)
ECM SERVICE PRECAUTIONS

The ECM is designed to withstand normal current draws
associated with engine operation. When servicing the
ECM, observe the following guidelines:
• Do not overload any circuit.
• Do not probe wires for testing. This can cause a volt-
age drop that affects ECM operation.
• When testing for opens and shorts, do not ground or
apply voltage to any of the ECM's circuits unless
instructed to do so.
• When measuring voltages, use only a digital voltmeter
with an input impedance of at least 10 megohms.
• Do not jump start with more than 12 volts. This can
damage electronic components.
• Do not use non-standard practices such as charging
the battery with an arc welder.
• Take precautions to avoid static damage to the ECM.
Refer to “Electrostatic Discharge Damage” for more
information.
3121180 – JLG Lift – 3-101

3.14 CIRCUIT TESTING TOOLS Fuel System

FUEL INJECTOR
The Electronic Fuel Injection (EFI) fuel injector is a sole-
DO NOT USE A TEST LIGHT TO DIAGNOSE ENGINE ELECTRICAL
noid-operated device controlled by the ECM. The ECM
SYSTEMS UNLESS SPECIFICALLY INSTRUCTED. A TEST LIGHT
energizes the solenoid, which opens a valve to allow fuel
CAN PUT AN EXCESSIVE LOAD ON AN ECM CIRCUIT AND
delivery.
CAUSE COMPONENT DAMAGE. ONLY USE A DIGITAL VOLTME-
TER WITH AN INPUT IMPEDANCE OF AT LEAST 10 MEGOHMS
Fuel is injected under pressure in a conical spray pattern
FOR VOLTAGE MEASUREMENTS.
at opening of the intake valve. Excess fuel not used by
injectors passes through the fuel pressure regulator
Electrostatic Discharge Damage before being returned to the fuel tank.
Electronic components used in the ECM are often A fuel injector stuck partly open will cause loss of fuel pres-
designed to carry very low voltage. Electronic compo- sure after engine is shut down, causing long crank times.
nents are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can
cause damage to some electronic components. By com-
parison, It takes as much as 4000 volts for a person to feel
the spark of a static discharge.
There are several ways for a person to become statically

charged. The most common are friction and induction.
An example of charging by friction is a person sliding FUEL METERING SYSTEM COMPONENTS

across a seat. The fuel metering system is made up of the following
parts:
Charge by induction occurs when a person with well-insu-
• Fuel injectors
lated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same polar- • Fuel rail
ity are drained off, leaving the person highly charged with
• Fuel pressure regulator/filter assembly
the opposite polarity. Static charges can cause damage,
therefore it is important to-use care when handling and • Electronic governor
testing electronic components. • ECM
Follow these guidelines to prevent possible electrostatic • Crankshaft position (CKP) sensor
discharge damage: • Camshaft position (CMP) sensor
• Do not touch ECM connector pins or soldered compo- • Fuel pump
nents on the ECM board.
• Fuel pump relay
• Do not open the replacement part package until the
part is ready to be installed. BASIC SYSTEM OPERATION
• Before removing the part from the package, ground The fuel metering system starts with fuel in the fuel tank.
package to a known good ground on equipment. Fuel is drawn to the fuel pump through a pre-filter. The
electric fuel pump then delivers fuel to the fuel rail through
• If part has been handled while sliding across a seat, an inline fuel filter. The pump is designed to provide fuel at
while sitting down from a standing position, or while a pressure above pressure needed by the injectors. A fuel
walking a distance, touch a known good ground pressure regulator in the fuel filter assembly keeps fuel
before installing part. available to the fuel injectors at a constant pressure. A
return line delivers unused fuel back to the tank.
3-102 – JLG Lift – 3121180

HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI.
Figure 3-62. Typical Fuel System
3121180 – JLG Lift – 3-103

FUEL METERING SYSTEM PURPOSE FUEL PUMP ELECTRICAL CIRCUIT

The basic function of the air/fuel metering system is to When key is first turned “ON,” the ECM energizes the fuel
control air/fuel delivery to the engine. Fuel is delivered to pump relay for two seconds to build up fuel pressure
the engine by individual fuel injectors mounted in the quickly. If engine is not started within two seconds, the
intake manifold near each intake valve. ECM shuts the fuel pump off and waits until engine is
cranked. When engine is cranked and crankshaft position
The main control sensor is the heated oxygen sensor
signal has been detected by the SECM, the ECM supplies
(H02S) located in the exhaust system. The H02S tells the
12 volts to the fuel pump relay to energize the electric fuel
ECM how much oxygen is in the exhaust gas. The ECM
pump.
changes air/fuel ratio to the engine by controlling the
amount of time the fuel injector is “ON.” The best mixture An inoperative fuel pump will cause a “no-start” condition.
to minimize exhaust emissions is 14.7 parts of air to 1 part A fuel pump which does not provide enough pressure
of gasoline by weight, which provides the most efficient causes poor performance.
combustion. Because of constant measuring and adjust-
ing of the air/fuel ratio, the fuel injection system is called a FUEL RAIL
“closed loop” system. The fuel rail is mounted to top of engine and distributes
fuel to individual injectors. Fuel is delivered to fuel inlet
The ECM monitors signals from several sensors in order tube of fuel rail by fuel lines.
to determine the fuel needs of the engine. Fuel is deliv-
ered under one of several conditions called “modes.” All
modes are controlled by the ECM. Refer to “Open Loop
and Closed Loop Operation” for more information.
FUEL PRESSURE REGULATOR

The fuel pressure regulator is a relief valve mounted in the
fuel filter. It provides a constant fuel pressure of 441 kPa
(64 psi).
If pressure is too low, poor performance and a DTC 32 will
set. If pressure is too high, excessive odor and/or a DTC
42 will result.
USE AN IDENTICAL FILTER/REGULATOR ASSEMBLY WHEN

REPLACING THE FUEL FILTER. A STANDARD FUEL FILTER
DOES NOT REGULATE PRESSURE AND COULD CAUSE ENGINE
PROBLEMS OR COMPONENT DAMAGE.
3-104 – JLG Lift – 3121180

ELECTRONIC GOVERNOR AND THROTTLE BODY OPEN LOOP AND CLOSED LOOP OPERATION
In the 2.5L EFI industrial engine, throttle control is The ECM operates in the following two modes:
achieved by using an electronic governor controlled by
• Open loop
the engine control module (ECM).
• Closed loop
When the engine is first started, the system is in “open
loop” operation. In open loop, the ECM ignores the
heated oxygen sensor (HO2S) signal. it uses a pre-pro-
grammed routine to calculate air/fuel ratio based on
inputs from the TP, ECT, and MAP sensors.
The system remains in open loop until the following condi-
tions are met:
• The HO2S has a varying voltage output showing it is
hot enough to operate properly.
• The ECT has reached 160°F (71°C).
• Seven minutes has elapsed since starting engine.
After these conditions are met, the engine is operating in
The electronic governor consists of a throttle body, an “closed loop.” In closed loop, The ECM continuously
electronically-actuated throttle plate, and a built-in throttle adjusts air/fuel ratio by responding to signals from the
position (TP) sensor. There are two pigtails that exit the HO2S (except at wide-open throttle). When the HO2S
governor body. The 3-wire pigtail connects the TP sensor reports a lean condition (low sensor signal voltage), the
to the ECM. Refer to “Throttle Position (TP) Sensor” for ECM enriches the mixture by increasing fuel injector “on”
more information. time. When the HO2S reports a rich condition (high sen-
sor signal voltage) the ECM leans out the mixture by
The 2-wire pigtail carries throttle signal from ECM to gov- reducing fuel injector “on” time.
ernor. Engine speeds are stored in the configuration pro-
gram for each specific application, and can be changed CAMSHAFT POSITION (CMP) SENSOR
with ECM calibration software. When engine speed is The CMP sensor uses a variable reactor sensor to detect
selected with the toggle switch, the ECM sends the appro- camshaft position. The CMP signal is created as piston #1
priate signal to the governor. This is a pulse-width modu- is a predetermined number of degrees after top dead cen-
lated (PWM) signal that cannot be read with conventional ter on the power stroke.
diagnostic tools such as a voltmeter. A 12-volt signal is
pulsed on and off at a high rate of speed. The width of the
“on” pulse determines throttle opening. The ECM sends a
signal with the appropriate pulse width to the governor
based on the operator's choice of switch settings.
The electronic governor also acts as an idle air control
(IAC) valve. Changes in engine load are detected by the
ECM by comparing manifold absolute pressure (MAP)
with throttle position. When the ECM detects a change in
engine load, it can adjust idle speed by changing the
PWM signal to the governor.
3121180 – JLG Lift – 3-105

CRANKSHAFT POSITION (CKP) SENSOR 3.15 DEUTZ ENGINE

The crankshaft position (CKP) sensor provides a signal used
NOTE: Refer to engine manufacturer’s manual for detailed
by the Engine Control Module (ECM) to calculate the ignition
operating and maintenance instructions.
sequence. The sensor initiates reference pulses which the
ECM uses to calculate RPM and crank-shaft position. Checking Oil Level
1. Make sure machine and engine are level and switch
engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level to MAX mark with an
approved grade and type of oil outlined in engine
manufacturer’s operator’s manual.
5. Replace dipstick until fully seated.
Changing Engine Oil
1. Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).
2. Make sure machine and engine are level and switch
off engine.
3. Place oil tray under engine.
ELECTRONIC IGNITION
The electronic ignition system controls fuel combustion by
providing a spark to ignite compressed air/fuel w mixture at HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT
the correct time. T he ECM controls ignition system spark OIL WHEN DRAINING.
advance to provide optimum engine performance, fuel
economy, and control of exhaust emissions.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL
IGNITION COIL
OR RECYCLING. DISPOSE OF USED ENGINE OIL IN ACCORDANCE
The electronic ignition system uses a coil pack with one
WITH ENVIRONMENTAL REGULATIONS.
ignition coil for each two cylinders. Each cylinder is paired
with its opposing cylinder in the firing order. One cylinder 4. Open oil drain valve and drain oil.
on compression fires simultaneously with the opposing 5. Close oil drain valve.
cylinder on exhaust. A spark that occurs in the cylinder on
exhaust stroke is referred to as a “waste spark.” 6. Pour in new engine oil. Refer to Section 1 for capac-
ity and refer to Figure 3-63., Engine Oil Viscosity.
Primary coils in the coil pack are triggered by “Ignition Coil
Feed #1” and “Ignition Coil Feed #2” ECM signals.
Figure 3-63. Engine Oil Viscosity
3-106 – JLG Lift – 3121180

Changing Oil Filter Replacing Fuel Filter

1. Wipe area around filter to clean any dirt from area.
2. Using a suitable oil filter removal tool, loosen lube oil
filter cartridge and spin off. MAKE SURE THERE ARE NO OPEN FLAMES OR SPARKS IN THE
AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE
WHEN WORKING ON FUEL SYSTEM.
1. Wipe area around filter to clean any dirt from area.

2. Undo fuel filter cartridge and spin off.
3. Catch any escaping fuel.
4. Clean any dirt from filter carrier sealing surface.
5. Apply a light film of oil or diesel fuel to rubber gasket
of new filter cartridge.
6. Screw in new filter by hand until the gasket is flush.
7. Hand-tighten filter another half-turn.
8. Open fuel shut-off valve.
3. Catch any escaping oil. 9. Check for leaks.
4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil. Cleaning Fuel Strainer
FUEL IS FLAMMABLE. MAKE SURE THERE ARE NO OPEN

FLAMES OR SPARKS IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1. Unscrew hexagonal nut (1).
6. Screw in new filter by hand until gasket is flush.
2. Remove fuel strainer cover (2).

3. Clean fuel strainer with diesel fuel and replace if nec-
essary.
7. Hand-tighten filter another half-turn. 4. Place seal (3) in position.
8. Check oil level. 5. Install fuel strainer cover (2) in position and tighten
hexagonal screw (1).
9. Check oil pressure.
6. Check for leaks.
10. Check oil filter cartridge for leaks.
3121180 – JLG Lift – 3-107

3.16 DEUTZ EMR 2 (S/N 85332 TO PRESENT) The EMR2 is equipped with safety devices and measures
in the hardware and software for emergency running
The EMR2 system consists of sensors, control unit, and (Limp home) functions.
an actuator. Engine-side controls and the JLG Control
To switch engine off, the EMR2 is switched in a de-ener-
System are connected by separate cable harnesses to the
gized fashion over the ignition switch. A strong spring in
EMR control unit.
the actuator presses the control rod in the de-energized
Engine sensors provide control unit electronics with infor- condition to the zero position. As a redundancy measure,
mation of the current condition of engine and precondi- an additional solenoid serves for switching off and this,
tions (throttle position etc.). The EMR2 controls an independently of the actuator, also moves the control rod
actuator that operates the injection pump control rod and in the de-energized condition into the zero position.
adjusts fuel quantity to meet performance requirements.
After programming over the ISO9141 interface, the EMR2
Regulating rod position is reported back and corrected by possesses a motor-specific data set matched by serial
the control rod travel sensor, situated together with rota- number to the engine. Modules cannot be swapped
tion magnets in the actuator housing. between engines.
CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE CAMSHAFT SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/

STOP; EMR2 TAKES CONTROL OF THE
ENGINE AT 700RPM
GLOW PLUG
JLG SYSTEM USES JLG ANALYZER TO

REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS;
JLG SYSTEM USES THIS TO CONTROL
OIL PRESSURE
ENGINE & FAULT REPORTING.
SENSOR
Figure 3-64. EMR 2 Engine Side Equipment
3-108 – JLG Lift – 3121180

Figure 3-65. Deutz EMR 2 Troubleshooting Flow Chart
3121180 – JLG Lift – 3-109

3-110
– JLG Lift –
Figure 3-66. Deutz EMR 2 Vehicle Side Connection Diagram
3121180
3121180
– JLG Lift –
Figure 3-67. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3-111
3-112
– JLG Lift –
Figure 3-68. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3121180
Figure 3-69. EMR 2 Engine Plug Pin Identification
3121180 – JLG Lift – 3-113

Figure 3-70. EMR 2 Vehicle Plug Pin Identification
3-114 – JLG Lift – 3121180

Figure 3-71. EMR2 Fault Codes - Sheet 1 of 5
3121180 – JLG Lift – 3-115

3-116 – JLG Lift – 3121180

3121180 – JLG Lift – 3-117

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3121180 – JLG Lift – 3-119

3.17 GM ENGINE GENERAL MAINTENANCE • Check ground and platform control stations to ensure
all warning indicator lights are functioning.
Drive Belt Maintenance Checking/Filling Engine Oil Level

The serpentine drive belt utilizes a spring loaded tensioner
which keeps the belt properly adjusted. The drive belt is
an integral part of the cooling and charging systems and
AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED
should be inspected frequently.
FULL MARK) CAN CAUSE AN OIL LEAK, A FLUCTUATION OR
When inspecting the belts check for: DROP IN THE OIL PRESSURE, AND ROCKER ARM “CLATTER” IN
THE ENGINE.
• Cracks or breaks
• Chunking of the belt
• Splits
CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL.
• Material hanging from the belt OIL LEVEL MUST BE MAINTAINED BETWEEN THE “ADD” MARK
AND “FULL” MARK ON THE DIPSTICK.
• Glazing and hardening
• Damaged or improperly aligned pulleys To ensure you are not getting a false reading, make sure
• Improperly performing tensioner the following steps are taken before checking oil level.
Check the belt tensioner by pressing down on the midway 1. Stop engine if running.
point of the longest stretch between pulleys. The belt 2. Allow sufficient time (approximately 5 minutes) for
should not depress beyond 1/2 inch (13mm). If the the oil to drain back into the oil pan.
depression is more than allowable adjust the tension.
3. Remove the dipstick. Wipe with a clean cloth or
paper towel and reinstall. Push the dipstick all the
way into the dipstick tube.
ENGINE MANUFACTURER DOES NOT RECOMMEND USE OF 4. Remove the dipstick and note the oil level.
“BELT DRESSING” OR “ANTI SLIPPING AGENTS” ON DRIVE
BELT. 5. Oil level must be between the “FULL” and “ADD”
marks.
Engine Electrical System Maintenance
The engine electrical system uses computers and micro-
processors to control engine ignition, fuel control, and
emissions. Periodic inspection of electrical wiring is
required due to sensitivity of computers to good electrical
connections. When inspecting electrical system:
• Check and clean battery terminal connections and
ensure connections are tight. Figure 3-76. Engine Oil Dip Stick
• Check battery for any cracks or damage to the case.
6. If oil level is below the “ADD” mark, go to Step 7 and
• Check positive and negative battery cables for corro- 8 and reinstall dipstick in dipstick tube.
sion, rubbing, or chafing. Check connection to chassis
is tight. 7. Remove oil filter cap from valve rocker arm cover.
8. Add required amount of oil to bring level up to, but
• Check entire engine wire harness for rubbing chafing,
not over, “FULL” mark on dipstick.
cuts, or damaged connections. Repair as needed.
9. Reinstall oil fill cap to valve rocker cover and wipe off
• Check all wire harness connectors are fully seated and
excess oil.
locked.
• Check ignition coil and spark plug cables for harden-
ing, cracking, chafing, separation, split boot covers
and proper fit.
• Replace spark plugs at the proper intervals as pre-
scribed in the engine manufacturer’s manual.
• Make sure all electrical components are fitted securely.
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Changing Engine Oil 1. Loosen worm gear clamp on coolant line running
into EPR as shown below and remove hose from
EPR. Place a rag under hose to prevent coolant from
running onto engine/machine.
ALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE
OIL WHEN ENGINE IS WARM FROM OPERATION AS OILS WILL
FLOW FREELY AND CARRY AWAY MORE IMPURITIES.
To change oil:
1. Start engine and run until it reaches normal operat-
ing temperature.
2. Stop engine.
3. Remove drain plug and allow oil to drain.
4. Remove and discard oil filter and its sealing ring.
5. Coat sealing ring on filter with clean engine oil and
wipe sealing surface on filter mounting surface to
remove dust, dirt and debris. Tighten filter securely
(follow filter manufacturers instructions). Do not over
tighten.
6. Check sealing ring on drain plug for damage,
replace if necessary, wipe plug with a clean rag, and 2. Remove radiator cap. Fill radiator with coolant until
wipe sealing surface on pan and reinstall pan plug. coolant starts to appear from previously removed
Do not over tighten. hose at EPR. Reinstall hose to EPR and continue to
7. Fill crankcase with oil. fill radiator with coolant.
8. Start engine and check for oil leaks.
9. Stop engine and check oil level is at “FULL”.
10. Properly dispose of oil and filter.
Coolant Fill Procedure - Dual Fuel Engine
DAMAGE TO ENGINE COULD OCCUR IF NOT PROPERLY FILLED

WITH COOLANT. LPG FUELED ENGINES ARE MOST PRONE TO
CREATING AN AIR LOCK DURING A COOLANT FILL OPERATION
DUE TO THE ELECTRONIC PRESSURE REGULATOR (EPR) BEING
THE HIGHEST POINT IN THE COOLING SYSTEM. AN EPR THAT
APPEARS TO HAVE FROST FORMING ON IT IS A SIGN THE
ENGINE COOLING SYSTEM CONTAINS AIR. APPEARANCE AND
TEMPERATURE OF THE EPR SHOULD BE MONITORED DURING
3. With radiator cap still removed, start engine and run
COOLANT FILL OPERATION. A WARM EPR IS AN INDICATION
until thermostat opens. Thermostat opens at 170° F
THAT THE COOLING SYSTEM IS PROPERLY FILLED AND FUNC-
(77° C), which can be checked using the JLG hand-
TIONING.
held analyzer.
MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY MAIN- WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRES-
TENANCE WORK. ENT COMING FROM RADIATOR. THIS IS NORMAL.
4. Run engine for 5 minutes after it reaches operating

temperature. Shut engine off and continue to step 5.
3121180 – JLG Lift – 3-121

Gasoline dual fuel system primary components are the

gasoline tank, electric fuel pump and filter, fuel supply line,
HEATED COOLANT MAY SPILL OUT DUE TO AIR “BURPING” OUT injector rail and injectors, and fuel pressure regulator.
OF SYSTEM WITH RADIATOR CAP OFF WITH ENGINE RUNNING
The LPG dual fuel system primary components are the
OR WHEN SHUTTING OFF ENGINE.
LPG fuel tank, in-fuel filter, LPG Low Pressure lock-off,
Electronic Pressure Regulator (EPR), and fuel mixer mod-
5. Verify two coolant hoses on the EPR are warm. If
ule. The LPG fuel system operates at pressures which
they are not warm repeat step 3 and 4, otherwise
range from 14.0 inches (355.60 mm) of water column up
continue to step 6.
to 312 psi (21.5 BAR).
Components shared by both systems include the Elec-
A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM tronic Throttle Control and ECM. The ECM contains a dual
UPPER RADIATOR HOSE AND A WARM EPR HOSE. IF UPPER calibration; one controls the gasoline fuel system during
RADIATOR HOSE AND/OR EPR HOSE ARE NOT WARM TO THE gasoline operation and one controls the LPG fuel system
TOUCH AFTER ENGINE HAS RUN FOR 5-8 MINUTES AFTER during LPG operation.
REACHING OPERATING TEMPERATURE, SYSTEM MAY STILL
CONTAIN AIR. IT MAY BE NECESSARY TO REPEAT ABOVE STEPS. Fuel Filter
Propane fuel, like other fuels, is subject to contamination
6. Fill radiator with coolant as needed and install radia-
from outside sources. Refueling and removal of the tank
tor cap. Remove cap off coolant recovery bottle and
from the equipment can inadvertently introduce dirt and
fill just below HOT FULL line. Reinstall caps.
other foreign matter into the fuel system. It is therefore
necessary to filter the fuel prior to entering the fuel system
components downstream of the tank. An inline fuel filter is
installed in the fuel system to remove the dirt and foreign
matter from the fuel. The inline filter is replaceable as a
unit only. Maintenance of the filter is critical to proper fuel
system operation and should be replaced as Section 1. In
severe operating conditions more frequent replacement of
the filter may be necessary.
Electric Lock Off

The Electric Lock Off device is an integrated assembly.
When energized the solenoid opens the valve and allows
Propane fuel to flow through the device. The valve opens
during cranking and run cycles of the engine. Lock off
supply voltage is controlled by the ECM.
3.18 GM ENGINE DUAL FUEL SYSTEM
The Dual Fuel system allows the operator to operate the
vehicle on either gasoline or LPG by positioning a selector
switch in the operator's platform. When the operator
places the selector switch in gasoline mode, the gasoline
fuel pump is energized. While in gasoline mode the LPG
fuel lock-off is isolated and will not energize. In addition,
the gasoline injector circuit is enabled and injector pulses
are provided to each injector and the ECM calibration for
gasoline is also enabled. When the operator selects the Figure 3-77. Electric Fuel Lock Off
LPG mode the Low Pressure LPG lock-off is energized
and fuel from the LPG tank flows to the Electronic Pres-
sure Regulator (EPR). The EPR receives an electronic sig-
nal to position the secondary lever for the start or run
positions and when the engine begins to crank the mixer
air valve will rise and fuel will begin flowing to engine. Dur-
ing this mode the gasoline fuel pump is isolated and will
not be activated.
3-122 – JLG Lift – 3121180

EPR Assembly Low Pressure Regulator (LPR)

The EPR assembly is a combination Low Pressure Regu- The LPR is a combination vaporizer, pressure regulating
lator and a Voice Coil Assembly. The Voice coil is an elec- device. The LPR is a negative pressure, two stage regula-
tronic actuator controlled by an internal microprocessor. tor that is normally closed when the engine is not running.
The microprocessor provides output data to the ECM and When the engine is cranking or running, a partial vacuum
receives input data over a CAN BUS connection. The is created in the fuel line which connects the regulator to
internal microprocessor receives electrical signals from the mixer. This partial vacuum opens the regulator permit-
the Fuel Pressure Sensor FPS and the Fuel Temperature ting fuel to flow to the mixer.
Pressure FTP and communicates the data to the ECM.
Propane fuel enters the primary port of the LPR and
The ECM uses FPS and FTP data to calculate location of
passes through the primary jet and into the primary/
the secondary lever in the LPR and sends that data back
exchanger chamber. As propane passes through the heat
to the EPR via the CAN BUS. The internal microprocessor
exchanger, the fuel expands and creates pressure inside
in the EPR will then output a signal, which causes the
the chamber. Pressure rises as fuel expands when pres-
voice coil to move and position the secondary lever to the
sure rises above 1.5 psi (10.34 kpa), sufficient pressure is
correct location.
exerted on the primary diaphragm to cause the dia-
phragm plate to pivot and press against the primary valve
pin thus closing off the flow of fuel. This action causes the
flow of fuel into the regulator to be regulated.
When engine is cranking, sufficient vacuum will be intro-
duced into the secondary chamber from the mixer draw-
ing the secondary diaphragm down onto the spring
loaded lever and opening the secondary valve allowing
vaporized fuel to pass to the mixer. This mechanical action
in conjunction with the EPR reactions causes the down-
ward action on the secondary lever causing it to open
wider allowing more fuel to flow to the mixer.
VOICE COIL SECTION OF EPR ASSEMBLY IS AN EMISSIONS

CONTROL DEVICE AND CANNOT BE REBUILT. IF COIL ASSEM-
BLY FAILS TO OPERATE PROPERLY, REPLACE WITH AN OEM
1. Pressure Regulator Section 4. Primary Test Port
REPLACEMENT PART ONLY.
2. Fuel Inlet 5. Secondary Test Port
3. Coolant Passage 6. Voice Coil Section
Figure 3-78. EPR Assembly
Figure 3-79. Low Pressure Regulators
3121180 – JLG Lift – 3-123

Air Fuel Mixer Electronic Throttle Control (ETC)

The air valve mixer is an air-fuel metering device and is Engine speed and load control is maintained by an ETC
completely self-contained. The mixer is an air valve device. Speed and load control are determined by the
design, utilizing a relatively constant pressure drop to ECM. Defaults programmed into the ECM software and
draw fuel into the mixer from cranking to full load. The throttle position sensors allow the ECM to maintain safe
mixer is mounted in the air stream ahead of the throttle operating control over the engine. The Electronic Throttle
control device. Control device or “throttle body assembly” is connected
to the intake manifold of the engine. The electronic throttle
When the engine begins to crank, it draws in air with the
control device utilizes an electric motor connected to the
air valve covering the inlet, negative pressure begins to
throttle shaft. When the engine is running electrical signals
build. This negative pressure signal is communicated to
are sent from the equipment controls to the engine ECM
the top of the air valve chamber through 4 vacuum ports in
when the operator depresses an equipment function
the air valve assembly. A pressure/force imbalance begins
switch. The ECM then sends an electrical signal to the
to build across the air valve diaphragm between the air
motor on the electronic throttle control to increase or
valve vacuum chamber and the atmospheric pressure
decrease the angle of the throttle blade thus increasing or
below the diaphragm. The air valve vacuum spring is cali-
decreasing the air/fuel flow to the engine.
brated to generate from 4.0 inches (101.6 mm) of water
column at start to as high as 14.0 inches (355.60 mm) of The electronic throttle control device incorporates two
water column at full throttle. The vacuum being created is internal Throttle Position Sensors (TPS) which provide
referred to as Air Valve Vacuum (AVV). As the air valve output signals to the ECM as to the location of the throttle
vacuum reaches 4.0 inches (101.6mm) of water column, shaft and blade. TPS information is used by the ECM to
the air valve begins to lift against the air valve spring. The correct speed and load control, and emission control.
amount of AVV generated is a direct result of the throttle
position. At low engine speed the air valve vacuum is low
and the air valve position is low thus creating a small ven-
turi for the fuel to flow. As engine speed increase the AVV
increases and the air valve is lifted higher creating a much
larger venturi. This air valve vacuum is communicated
from the mixer venture to the LPR secondary chamber via
the low pressure fuel supply hose. As the AVV increases in
the secondary chamber the secondary diaphragm is
drawn further down forcing the secondary valve lever to
open wider.
Figure 3-81. ETC throttle control device
Figure 3-80. Air Fuel Mixer
3-124 – JLG Lift – 3121180

Engine Control Module Heated Exhaust Gas Oxygen Sensor

To obtain maximum effect from the catalyst and accurate There are two Heated Exhaust Gas Oxygen Sensors
control of the air fuel ratio the emission certified engine is (HEGO). The first HEGO is mounted in the exhaust system
equipped with an onboard computer or Engine Control downstream of the engine. It measures the amount of oxy-
Unit (ECM). The ECM is a 32 bit controller which receives gen present in the exhaust stream and communicate that
input data from sensors fitted to the engine and fuel sys- to the ECM via an electrical signal. The amount of oxygen
tem and then outputs various signals to control engine present in the exhaust stream indicates whether the fuel/
operation. air ratio is too rich or too lean. If the HEGO sensor signal
indicates that the exhaust stream is too rich the ECM will
One specific function of the controller is to maintain
decrease or lean the fuel mixture during engine operation,
“closed loop fuel control”. Closed loop fuel control is
if the mixture is too lean the ECM will richen the mixture.
accomplished when the Hot Exhaust Gas Oxygen sensor
The ECM continuously monitors the HEGO sensor output.
(HEGO) mounted in the exhaust system sends a voltage
If a rich or lean condition is present for an extended period
signal to the controller. The controller calculates correc-
of time, and the ECM cannot correct the condition, the
tions needed for the air fuel ratio. The controller then out-
ECM will set a diagnostic code and turn on the MIL light in
puts signals to the EPR to correct amount of fuel supplied
control box.
to the mixer. At the same time, the ECM may correct the
throttle blade position to correct speed and load of the The second HEGO is mounted in the exhaust system after
engine. the muffler. It measures the amount of oxygen in the
exhaust system after the catalyst treatment has been com-
The controller also performs diagnostic functions on the
pleted in the muffler. If the ECM detects that the catalytic
fuel system and notifies the operator of malfunctions by
action in the muffler is not sufficient and fuel correction
turning on a Malfunction Indicator Light (MIL) mounted in
cannot correct the malfunction the MIL light is illuminated
the Ground Control Station and Platform Control Station.
in the control box and a DTC code will stored in the com-
Malfunctions in the system are identified by a Diagnostic
puter.
Code number. In addition to notifying the operator of a
system malfunction the controller also stores malfunction
information in its memory.
HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION CON-
TROL DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE IT
WITH AN OEM REPLACEMENT PART. HEGO SENSOR IS SENSI-
TIVE TO SILICONE OR SILICONE BASED PRODUCTS AND CAN
BECOME CONTAMINATED. AVOID USING SILICONE SEALERS OR
HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR
STREAM OR FUEL LINES.
Figure 3-82. LPG Engine Control Unit (ECM)
Figure 3-84. Heated Exhaust Gas Oxygen Sensor

(HEGO)
Gasoline Multi Point Fuel Injection System

(MPFI)
The primary components of the Gasoline Multi Point Fuel
Figure 3-83. ECM Assembly
Injection (MPFI) fuel system are the fuel tank, electric fuel
pump, fuel pressure and temperature sensor manifold,
fuel filter, and fuel rail.
3121180 – JLG Lift – 3-125

Gasoline Fuel Pump Fuel Filter

The Gasoline is stored as a liquid in the fuel tank and in After fuel is drawn into the fuel pump, the fuel flows
drawn into the fuel system by an electric fuel pump. The through the gasoline fuel filter. The fuel filter traps small
fuel pump receives a signal from the ECM to prime the particles as the fuel passes through the filter to remove
fuel system for approximately 2 seconds prior to start. debris and prevents the fuel pressure and temperature
Priming the fuel system provides for a quicker start when manifold and fuel injectors from becoming damaged.
the engine begins to crank. Maintenance of the fuel filter is required as indicated in
Section 1.
Gasoline Pressure And Temperature Sensor
Manifold Fuel Injector Rail
Fuel flows from the fuel pressure and temperature mani-
This engine is equipped with a fuel injector rail that does
fold assembly to the fuel rails where the fuel is delivered to
not have a pressure regulator or a return circuit to the fuel
the fuel injectors. The fuel rail also contains a Schrader
tank. Fuel pressure is regulated by the engine’s ECM. The
valve which is utilized to test the regulated pressure of the
ECM receives fuel pressure and temperature feedback
fuel system.
from the gasoline fuel sensor manifold and uses this infor-
mation to control the ground side of the fuel pump. Fuel
pressure is regulated by the ECM pulse width modulating Fuel Injector
(PWM) the fuel pump. The fuel pressure and temperature
The fuel supply is maintained on the top of the injector
sensor manifold has a return or “bleed” circuit that con-
from the injector rail. The injector is fed a “pulse” signal
nects back to the fuel tank. This circuit bleeds off any
through the wire harness which causes the injector to
vapor that develops in the line and returns a small amount
open. During regular operating conditions the ECM con-
of fuel to the tank. Fuel comes from the fuel tank and
trols the opening and duration of opening of the injector.
passes through the fuel pump. Fuel exits the fuel pump,
During lower RPM operation the injector signals or
passes through the filter and then enters the fuel pressure
“pulses” are less frequent then when the engine is operat-
and temperature manifold assembly. Fuel flows through
ing at higher RPM’s. The engine has been calibrated to
the feed circuit and is delivered to the fuel injector rail.
deliver the precise amount of fuel for optimum perfor-
Fuel that enters bleed circuits through manifold bypass
mance and emission control.
valve returns to the fuel tank.
3.19 GM ENGINE FUEL SYSTEM REPAIR
Propane Fuel System Pressure Relief
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO

312 PSI (21.5 BAR). TO MINIMIZE RISK OF FIRE AND PERSONAL
INJURY, RELIEVE PROPANE FUEL SYSTEM PRESSURE (WHERE
APPLICABLE) BEFORE SERVICING PROPANE FUEL SYSTEM
COMPONENTS.
To relieve propane fuel system pressure:

1. Close the manual shut-off valve on the propane fuel
tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
RESIDUAL VAPOR PRESSURE IS PRESENT IN THE FUEL SYS-

TEM. ENSURE WORK AREA IS WELL VENTILATED BEFORE DIS-
CONNECTING ANY FUEL LINE.
Figure 3-85. Gasoline Fuel Pressure and Temperature
Manifold Assembly
3-126 – JLG Lift – 3121180

Propane Fuel System Leak Test 6. Locate filter magnet (4) and remove it.
7. Remove and discard housing seal (3).
8. If equipped, remove and discard retaining bolt seal.
PROPANE IS EXTREMELY FLAMMABLE. NEVER USE AN OPEN FLAME 9. Remove and discard mounting plate to lock off O-ring (9).
OF ANY TYPE TO CHECK FOR PROPANE FUEL SYSTEM LEAKS.
Always inspect propane fuel system for leaks after per- Installation
forming service. Check for leaks at fittings of serviced or
replaced components. Use a commercially available liq- NOTE: Reinstall filter magnet in housing before installing
uid leak detector or electronic leak detector. If using both new seal
methods, use the electronic leak detector first to avoid
contamination by the liquid leak detector. 1. Install mounting plate to lock off O-ring (9).
2. If equipped, install retaining bolt seal.
Propane Fuel Filter Replacement
3. Install housing seal (3).
Removal 4. Drop magnet (4) into bottom of filter housing (5).

5. Install filter into housing (5).
1. Relieve propane fuel system pressure. Refer to Pro-
pane Fuel System Pressure Relief. 6. If equipped, install retaining bolt into filter housing.
2. Disconnect negative battery cable. 7. Install filter up to bottom of electric lock off.
3. Slowly loosen filter housing (5) and remove it. 8. Tighten filter bowl retainer to 106 in-lb (12 Nm).
4. Pull filter housing from electric lock off assembly. 9. Open manual shut-off valve. Start vehicle and leak
check propane fuel system at each serviced fitting.
5. Remove filter from housing. Refer to Propane Fuel System Leak Test.
1 7 1 7
8 8
2 13
9 9
3 3
10 10
4 OR 4
5 5
11
6
11
12
1. Electric Lock Off Solenoid 6. Seal 10. Filter

2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet
3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt
4. Filter Magnet 9. O-ring 13. Ring
5. Filter Housing
Figure 3-86. Filter Lock Assembly
3121180 – JLG Lift – 3-127

Electronic Pressure Regulator (EPR) INSTALLATION
Assembly Replacement
The EPR assembly consists of two separate components. DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQUID
The Voice Coil Section is not serviceable and can only be PIPE THREAD SEALANT WHEN INSTALLING FITTINGS.
replaced as an assembly. The pressure regulator section
is serviceable and is detailed in this section. CHECK ALL O-RINGS ON VAPOR AND WATER FITTINGS FOR ANY
DAMAGE. REPLACE IF NECESSARY.
LUBE ALL O-RINGS WITH AN O-RING LUBE BEFORE INSTALLING.
1. Install three rubber isolators to bottom of EPR

2. Install EPR assembly to bracket and tighten retain-
ing nuts.
NOTE: Do not over tighten the isolators and cause a separa-

tion of the isolators.
3. Install fuel temperature sensor into regulator open-

ing and lock in place with locking pin. Connect elec-
trical connector.
4. Insert fuel vapor line and fitting into regulator port.
Lock in place with locking pin.
1. Pressure Regulator Section 4. Primary Test Port 5. Install water hoses and fittings into regulator. Lock in
2. Fuel Inlet 5. Secondary Test Port place with locking pin. Remove clamp pliers from
3. Coolant Passage 6. Voice Coil Section hoses.
Figure 3-87. EPR Assembly 6. Install electric lock off into regulator inlet and tighten
into proper location. Connect electrical connector.
REMOVAL 7. Connect fuel supply line and tighten until fully

seated.
1. Relieve propane fuel system pressure. Refer to Pro-
8. Connect EPR electrical connector.
pane Fuel System Pressure Relief.
9. Open manual valve.
2. Disconnect negative battery cable.
10. Start vehicle and leak check propane fuel system at
3. Slowly remove fuel inlet fitting at Electric Lock Off.
each serviced fitting. Refer to Propane Fuel System
NOTE: Fuel system will have residual vapor pressure. Leak Test.
4. Disconnect electrical connector from Electric Lock Off.

5. Remove Electric Lock Off from regulator.
6. Remove lock pin from vapor fitting on regulator
housing. Remove fitting and hose. Retain pin.
7. Remove lock pin from pressure sensor on regulator
housing and remove sensor. Retain pin.
8. Pinch off hoses on coolant lines to regulator using
clamp pliers.
9. Remove lock pin water fittings on regulator housing.
Remove fittings and hoses. Retain pin. Figure 3-88. Pressure Regulator Section
10. Disconnect EPR electrical connector
11. Remove three nuts from EPR isolators and EPR
mounting bracket
12. Remove EPR from bracket
13. Remove three mounting isolators.
3-128 – JLG Lift – 3121180

PRESSURE REGULATOR SECTION REMOVAL Electronic Throttle Control Replacement

1. Remove EPR. Refer to EPR Removal Procedure. See Figure 3-89.
2. Remove six (6) regulator to voice coil screws using
the special tool. Separate regulator from actuator. REMOVAL
1. Disconnect negative battery cable.
2. Remove air intake duct.
DO NOT REMOVE SECONDARY DIAPHRAGM RETAINING PLATE
AND DIAPHRAGM OR ACTUATOR SECTION WARRANTY WILL BE 3. Release hose clamp on vapor fuel line and remove
VOID. vapor hose.
4. Disconnect TMAP electrical connector.
PRESSURE REGULATOR SECTION INSTALLATION
5. Disconnect electronic throttle control connector.
1. Install regulator to actuator section with six (6) 6. Remove manifold to throttle body adapter bolts and
retaining screws. Tighten to 70 in-lb (8 Nm). remove throttle body mixer assembly.
2. Install EPR. Refer to EPR Installation. 7. Pull throttle body assembly from adapter.
8. Remove electronic throttle control device.
Temperature Manifold Absolute Pressure
9. Remove and discard O-rings.
(TMAP) Sensor
INSTALLATION
LIGHTLY LUBRICATE THROTTLE CONTROL DEVICE TO ADAPTER

O-RINGS.
1. Install O-ring on throttle body. Slide down to bottom

of surface.
Figure 3-89. (TMAP) Sensor & Electronic Throttle

Control (ETC)
REMOVAL
1. Disconnect TMAP electrical connector.
2. Remove two retaining bolts.
3. Remove TMAP.
INSTALLATION
NOTE: Apply a small amount of O-ring lubricant before

installation. Continued on next page.
1. Install TMAP.
2. Tighten retaining bolts to 62 in-lb (7 Nm).
3. Start vehicle and check for proper operation.
3121180 – JLG Lift – 3-129

2. Install two quad seals one seal at a time so seal MIXER REPLACEMENT
does not roll. Seal must sit flat on throttle body.
See Figure 3-90.
REMOVAL
1. Remove Throttle control device. Refer to Electronic
Throttle Body Replacement.
2. Remove four (4) throttle control device to mixer
adapter bolts.
3. Remove discard mixer to adapter gasket.
INSTALLATION
COVER THROTTLE BODY ADAPTER OPENING TO PREVENT

DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY.
1. Install Mixer to adapter gasket on mixer.

3. Attach mixer and throttle body together. The two 2. Install mixer on throttle control device to mixer
parts do not bolt together; they will be secured when adapter and secure with 4 retaining screws. Tighten
you mount it on intake. Note orientation of air inlet 80 in-lb(9 Nm)
and throttle body cover.
3. Install Throttle body. Refer to Electronic Throttle
Control Device Replacement.
4. Start engine and leak check all fittings and connec-
tions.
Coolant Hose Replacement

REMOVAL
1. Drain coolant.
2. Using hose clamp pliers, disconnect both hose
clamps on each hose.
3. Remove hose from each fitting.
INSTALLATION
NOTE: Use hose material and lengths specified by JLG.
4. Place gasket on intake manifold and attach mixer/ 1. Install hose clamps to each hose. Set clamp back
throttle assembly to manifold. on each hose to make installation easier.
2. Install hoses on fittings.
3. Secure by positioning each clamp.
Figure 3-90. Mixer Assembly
3-130 – JLG Lift – 3121180

Vapor Hose Replacement Heated Exhaust Gas Oxygen Sensor

REMOVAL Replacement
1. Disconnect hose clamps using hose clamp pliers. REMOVAL
2. Remove the vapor hose from each fitting. 1. Disconnect negative battery cable.
INSTALLATION 2. Disconnect the O2 sensor electrical connector.
3. Using an O2 Sensor socket, remove the O2 Sensor
and discard.
THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT INSTALLATION
USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED
PARTS.
1. Install hose clamps and set back on each hose. BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH
ANTI-SEIZE COMPOUND GM P/N 5613695 OR EQUIVALENT.
2. Reinstall vapor hose to each fitting.
AVOID GETTING COMPOUND ON THE SENSOR TIP.
3. Reset clamps.
4. Start engine and check for leaks. 1. Install O2 sensor. Tighten to 30 ft-lb (41 Nm).
2. Start engine.
Engine Control Module Replacement 3. Check and clear DTC codes.
REMOVAL 4. Verify engine is in closed loop and no warning lights
are illuminated.
1. Disconnect Negative battery cable.
2. Remove controller from mounting bracket.
3. Push connector lock back to unlock connector.
4. Unplug and remove controller.
INSTALLATION
THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY

YOU HAVE THE CORRECT CONTROLLER
1. Plug connector into controller.

2. Push lock into place.
3. Mount controller into mounting bracket.
4. Reconnect the battery cable.
5. Start engine.
6. Check for any DTC codes and clear.
7. Verify engine is in closed loop and no warning lights
are illuminated.
3121180 – JLG Lift – 3-131

3.20 GM ENGINE LPG FUEL SYSTEM Diagnostic Aids

DIAGNOSIS This procedure is for diagnosing a vehicle operating on
LPG. If the vehicle will not continue to run on LPG, refer to
Fuel System Description Hard Start for preliminary checks. Before proceeding with
this procedure, verify vehicle has sufficient quantity of fuel
and liquid fuel is being delivered to the LPR. Ensure LPG
tank manual shut off valve is fully opened and excess flow
valve has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs)
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light
Diagnostic Scan Tool
• Diagnostic Display tool.
Figure 3-91. EPR Assembly Pressure Gauges
• IMPCO ITK-2 Test kit
The LPG fuel system Engine Control Unit (ECM) relies on • Water Column Gauge / Manometer (GM 7333-6 or
engine sensors and output data from the Electronic Pres- equivalent).
sure Regulator (EPR) to maintain fuel and emission con-
trol. The ECM determines target fuel calibration and • 0-10 PSI Gauge
commands the EPR to reposition the voice coil to the Test Description
proper position which, subsequently reposition the sec-
ondary lever in the pressure regulator to maintain proper Numbers below refer to step numbers on the diagnostic
control. The EPR and ECM continue to communicate dur- table.
ing normal operation. 5. This step determines if LPR requires replacement
If the EPR fails to communicate or the Communications 6. This step determines if problems are in mechanical side
Area Network (CAN) cable fails to transmit data, the regu- of Pressure Regulator or Electronic Voice Coil
lator will operate in an open loop configuration. As the air
valve vacuum in the mixer venturi is communicated to the 10. This step determines if Mixer requires replacement
secondary chamber of the regulator, the secondary dia- 14. This step determines if Lock Off requires replacement
phragm will be drawn in a downwards motion. This down-
ward motion will cause the secondary lever to open and 17. This step determines if Fuel Filter requires replacement.
allow more fuel to enter the mixer.
In the Low Pressure Regulator (LPR) fuel is vaporized and
pressure reduced in two stages. The first stage reduces
pressure to approximately 1.0 to 3.0 psi (6.8 to 20.6 kPa).
The second stage reduces pressure to approximately
negative 1.5" of water column.
Fuel is then drawn from the secondary chamber of the
LPR by vacuum generated from air flowing through the
mixer. This vacuum signal is also used to generate lift for
the mixer air valve. This vacuum signal is most commonly
referred to as air valve vacuum. In the mixer, fuel mixes
with air entering the engine. This air/ fuel mixture is then
drawn into the engine for combustion.
3-132 – JLG Lift – 3121180

Table 3-14. LPF Fuel System Diagnosis
STEP ACTION VALUE(S) YES NO

1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2
2 Perform On Board Diagnostic (OBD) System Check. -- Gotothe Go to Step 3
Are any DTCs present in the ECM? applicable DTC Table
3 Verify LPG fuel tank has a minimum of 1/4 tank of fuel, manual valve is open and -- Go to Step 4 --
tank quick connect is fully engaged
Does vehicle have fuel?
4 1. Connect a water column gauge or a manometer to Low Pressure Regulator -- Go to Step 5 Go to Step 8
(LPR) secondary test port.
2. Start engine and allow it to reach operating temperature.
Does engine start and run?
5 With engine idling, observe pressure reading for LPR secondary pressure. -1.0" to Go to Step 25 Go to Step 6
Does fuel pressure fluctuate rhythmically OUTSIDE specified range? -2.0" w.c
6 1. Disconnect EPR electrical connectors. NOTE: This action will cause a DTC to -1.0" to Go to Fuel Control Go to Step 7
be set by the ECM -2.0" w.c System Diagnosis
2. With engine idling, observe pressure reading on secondary test port.
Is fuel pressure WITHIN specified range?
7 1. Inspect air intake stream between mixer assembly and throttle body for leaks. -- Go to Step 26 Go to Step 22
2. Inspect fuel hose connection between LPR and mixer assembly for damage
or leakage.
3. Inspect vacuum hoses for leaks
Was a problem found and corrected?
8 1. Connect a water column gauge or a manometer to LPR secondary test port. -- Go to Step 12 Go to Step 9
2. Crank engine and observe pressure reading for LPR secondary pressure.
Does fuel pressure indicate a vacuum is present?
9 1. Remove Air induction hose to mixer -- Go to Step 11 Go to Step 10
2. Observe air valve for movement while engine is cranking. Note: Movement of
air valve will be minimal at cranking speeds.
Does air valve move when engine is cranked?
10 1. Inspect air intake stream to mixer assembly and throttle body for vacuum -- Go to Step 26 Go to Step 24
leaks.
2. Inspect vacuum hoses from mixer for proper connection and condition.
Was a problem found and repaired?
11 Inspect fuel hose connection between LPR and mixer assembly for damage or -- Go to Step 26 Go to Step 12
leakage.
Was a problem found and repaired?
12 1. Connect a 0-10 psi gauge to primary test port of LPR. 1- 3 PSI Go to Step 22 Go to Step 13
2. Crank engine and observe pressure reading for LPR primary pressure.
Is fuel pressure ABOVE specified value?
13 1. Turn OFF ignition. -- Go to Step 14 Go to Step 16
2. Disconnect LPL connector.
3. Install a test light between pins of LPL connector.
4. Crank engine. Test light should illuminate.
Does test light illuminate?
14 Using a DVOM, check resistance of Low Pressure Lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23
Is resistance within specified range?
3121180 – JLG Lift – 3-133

Table 3-14. LPF Fuel System Diagnosis
STEP ACTION VALUE(S) YES NO

15 1. Turn ignition OFF. -- Go to Step 23 Go to Step 17
2. Close LPG tank manual shut-off valve.
LIQUID LPG MAY BE PRESENT WHEN DISCONNECTING LPG FUEL

LINES. PERFORM THIS STEP IN A WELL VENTILATED AREA.
3. Loosen fuel inlet hose fitting at LPL inlet.

Was fuel present when fitting was loosened?
16 1. Turn OFF ignition. -- Go to Step 20 Go to Step 21
2. Connect test light to chassis ground and probe pin A of LPL connector.
3. Crank engine. Test light should illuminate.
Does test light illuminate?
17 1. Remove LPG fuel filter / LPL. -- Go to Step 19 Go to Step 18
2. Remove filter from LPL.
3. Empty contents of inlet side of fuel filter onto a clean surface.
4. Inspect contents of LPG fuel filter for an excessive amount of foreign material
or water. If necessary, locate and repair source of contamination.
5. Verify LPG fuel filter is not restricted or plugged.
Was a problem found?
18 Fuel supply system or hoses are plugged or restricted. Locate and repair the -- Go to Step 26 --
problem.
Is action complete?
19 Replace fuel filter. Refer to Fuel Filter Replacement. -- Go to Step 26 --
Is action complete?
20 Repair open circuit in lock-off ground circuit. -- Go to Step 26 --
Is action complete?
21 Repair open circuit in lock-off power circuit. -- Go to Step 26 --
Is action complete?
22 Replace LPR. Refer to Low Pressure Regulator Replacement. -- Go to Step 26 --
Is action complete?
23 Replace Lock-Off. Refer to Lock-off Replacement. -- Go to Step 26 --
Is action complete?
24 Replace mixer assembly. Refer to Fuel Mixer Replacement. -- Go to Step 26 --
Is action complete?
25 Fuel supply system is operating normally, if a failure of the control solenoids is -- System OK --
suspected. Refer to Fuel Control System Diagnosis.
1. Install test plug in LPR secondary chamber.

2. If you were sent to this routine by another diagnostic chart, return to previous
diagnostic procedure.
Is action complete?
26 1. Disconnect all test equipment -- System OK --
2. Install primary and secondary test port plugs.
3. Start engine.
4. Using SNOOP or equivalent, leak check test port plugs.
Is action complete?
3-134 – JLG Lift – 3121180

Table 3-15. Symptom Diagnosis
Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. Visual and physical checks are
very important. These checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check 1. Verify customer complaint.
2. Locate correct symptom table.
3. Check items indicated under that symptom.
4. Operate vehicle under conditions the symptom occurs. Verify HEGO switching between lean and rich.
IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at
that time.
Visual and Physical Checks 1. Check all ECM system fuses and circuit breakers.
2. Check the ECM ground for being clean, tight and in its proper location.
3. Check the vacuum hoses for splits, kinks and proper connections.
4. Check thoroughly for any type of leak or restriction.
5. Check for air leaks at all mounting areas of intake manifold sealing surfaces.
6. Check for proper installation of the mixer module assembly.
7. Check for air leaks at mixer assembly.
8. Check ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
9. Check wiring for the following items:
- Proper connections, pinches or cuts.
The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not
important. If scan tool readings do not indicate problems, proceed in a logical order, easiest to check or most likely to
cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks Refer to Important Preliminary Checks. Do not use DTC tables. If a fault is intermittent, use of DTC tables may result in
replacement of good parts.
Faulty Electrical Connections or Faulty electrical connections or wiring can cause most intermittent problems.
Wiring 1. Check suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
2. Carefully remove all connector terminals in the problem circuit to ensure proper contact tension. If necessary, replace
all connector terminals in the problem circuit to ensure proper contact tension. Checking for poor terminal to wire connec-
tions requires removing terminal from connector body.
Operational Test If a visual and physical check does not locate cause of the problem, drive vehicle with a scan tool. When problem occurs,
an abnormal voltage or scan reading indicates the problem may be in that circuit.
3121180 – JLG Lift – 3-135

Checks Action
Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s):
Lamp (MIL) 1. A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally,
the problem will occur when the faulty component is operating.
2. Improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
3. Ignition secondary voltage shorted to a ground.
4. Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
5. Control Module grounds.
Loss of DTC Memory To check for the loss of DTC Memory:
1. Disconnect TMAP sensor.
2. Idle engine until Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in memory when ignition is turned OFF. If the TMAP
DTC does not store and remain, the ECM is faulty
Additional Checks
No Start
DEFINITION: Engine cranks OK, but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
1. Check for proper communication with both the ECM
2. Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
3. Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify volt-
age and/or continuity for each circuit.
Sensor Checks 1. Check TMAP sensor.
2. Check magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
1. Check for air intake system leakage between mixer and throttle body.
2. Verify proper operation of low pressure lock-off solenoids.
3. Check fuel system pressures. Refer to LPG Fuel System Diagnosis.
4. Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating
conditions.
1. Check proper ignition voltage output with J 26792 or equivalent.
2. Verify spark plugs are correct for use with LPG (R42LTS)
3. Check spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
4. Check for bare or shorted ignition wires.
5. Check for loose ignition coil connections at the coil.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
ifold leakage than a gasoline fuel supply system.
Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
3-136 – JLG Lift – 3121180

Checks Action
Exhaust System Checks 1. Check exhaust system for a possible restriction:
- Inspect exhaust system for damaged or collapsed pipes
- Inspect muffler for signs of heat distress or internal failure.
2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
Hard Start
DEFINITION: Engine cranks OK, but does not start for a long time. Engine does eventually run or may start, but immediately dies.
Preliminary Checks 1. Refer to Important Preliminary Checks.
2. Make sure operator is using correct starting procedure.
Sensor Checks 1. Check Engine Coolant Temperature (ECT) sensor with scan tool. Compare engine coolant temperature with ambient
air temperature on a cold engine. IF coolant temperature reading is more than 5 degrees greater or less than ambient air
temperature on a cold engine, check for high resistance in coolant sensor circuit. Refer to DTC 111
2. Check Crankshaft Position (CKP) sensor.
3. Check the Throttle Position Sensor (TPS).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
1. Verify excess flow valve in LPG manual shut-off valve is not tripped.
2. Check mixer module assembly for proper installation and leakage.
3. Verify proper operation of low pressure lock-off solenoids.
4. Verify proper EPR operation.
5. Check for air intake system leakage between mixer and throttle body.
6. Check the fuel system pressures. Refer to Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for equivalent gasoline operating
conditions.
1. Check proper ignition voltage output with J 26792 or the equivalent.
3. Check spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
4. Check for bare or shorted ignition wires.
5. Check for moisture in distributor cap if applicable.
6. Check for loose ignition coil connections.
NOTICE:
1. If engine starts but then immediately stalls, Check Crankshaft Position (CKP).
2. Check for improper gap, debris, or faulty connections.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
1. Check for the following:
- Vacuum leaks
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
2. Check intake and exhaust manifolds for casting flash.
3121180 – JLG Lift – 3-137

Checks Action
Exhaust System Checks 1. Check exhaust system for a restriction:
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect muffler for signs of heat distress or internal failure.
2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in GM Base
Engine Service Manual.
Additional Checks
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as engine load increases which is not normally felt above 1500 RPM.
Exhaust has a steady spitting sound at idle, low speed, or hard acceleration for fuel starvation that can cause the engine to cut-out.
Ignition System Checks 1.Start engine.
2. Wet down secondary ignition system with water from a spray bottle and look/listen for arcing or misfiring as you apply
water.
3. Check for proper ignition output voltage with spark tester J 26792.
4. Check for a cylinder misfire.
6. Remove spark plugs in these cylinders and check for the following conditions:
- Insulation cracks.
- Wear.
- Improper gap.
- Burned electrodes.
- Heavy deposits.
7. Visually/Physically inspect secondary ignition for the following:
- Ignition wires for arcing, cross-firing and proper routing.
- Ignition coils for cracks or carbon tracking.
Engine Mechanical Checks 1. Perform a cylinder compression check.
2. Check engine for the following:
- Bent pushrods.
- Worn rocker arms.
- Broken or weak valve springs.
3. Check intake and exhaust manifold passages for casting flash.
Fuel System Checks 1. Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
2. Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
- EMI on reference circuit can cause a missing condition.
- Monitoring engine RPM with a scan tool can detect an EMI.
- A sudden increase in RPM with little change in actual engine RPM indicates EMI is present.
- If problem exists, check routing of secondary wires and ground circuit.
3-138 – JLG Lift – 3121180

Checks Action
Hesitation, Sag, Stumble
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition
may cause the engine to stall if it' s severe enough.
Fuel System Checks 1. Check fuel pressure. Refer to LPG Fuel System Diagnosis.
2. Check for low fuel pressure during a moderate or full throttle acceleration. If fuel pressure drops below specification,
there is possibly a faulty low pressure regulator or a restriction in the fuel system.
3. Check Manifold Absolute Pressure (MAP) sensor response and accuracy.
4. Check LPL electrical connection
5. Check mixer air valve for sticking or binding.
6. Check mixer module assembly for proper installation and leakage.
7. Check EPR electrical connections.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages than equivalent gasoline operating
conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of an LPG only ignition system
failure and test system accordingly.
1. Check for proper ignition voltage output with J 26792 or the equivalent.
3. Check for faulty spark plug wires
4. Check for fouled spark plugs.
Additional Check 1. Check for manifold vacuum or air induction system leaks
2. Check generator output voltage.
Backfire
DEFINITION: Fuel ignites in the intake manifold or exhaust system, making a loud popping noise.
Preliminary Check Refer to Important Preliminary Checks.
Ignition System Checks NOTE: LPG, being a gaseous fuel, requires higher secondary ignition system voltages for than equivalent gasoline oper-
ating conditions. The ignition system must be maintained in peak condition to prevent backfire.
1. Check for proper ignition coil output voltage using spark tester J26792 or equivalent.
2. Check spark plug wires by connecting an ohmmeter to ends of each wire in question. If meter reads over 30,000 ohms,
replace wires.
3. Check connection at each ignition coil.
4. Check for deteriorated spark plug wire insulation.
5. Check spark plugs. Correct spark plugs for LPG are (R42LTS)
6. Remove and inspect plugs for the following conditions:
- Wet plugs.
- Cracks.
- Wear.
- Improper gap.
- Heavy deposits.
Engine Mechanical Check NOTE: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold
leakage than a gasoline fuel supply system.
1. Check engine for the following:
- Improper valve timing.
- Engine compression.
- Manifold vacuum leaks.
- Intake manifold gaskets.
- Sticking or leaking valves.
- Exhaust system leakage.
2. Check intake and exhaust system for casting flash or other restrictions.
Fuel System Checks Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
3121180 – JLG Lift – 3-139

Checks Action
Lack of Power, Sluggishness, or Sponginess
DEFINITION: Engine delivers less than expected power. There is little or no increase in speed when partially applying accelerator pedal.
2. Refer to LPG Fuel system OBD System Check
3. Compare customer' s vehicle with a similar unit. Make sure customer has an actual problem. Do not compare power
output of vehicle operating on LPG to a vehicle operating on gasoline as fuels have different drive feel characteristics.
4. Remove air filter and check for dirt or restriction.
5. Check vehicle transmission Refer to OEM transmission diagnostics.
Fuel System Checks 1. Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
2. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
3. Check for proper installation of the mixer module assembly.
4. Check all air inlet ducts for condition and proper installation.
5. Check for fuel leaks between the LPR and the mixer.
6. Verify that the LPG tank manual shut-off valve is fully open.
7. Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks 1. Check Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance.
2. Check proper operation of MAP sensor.
3. Check proper operation of TPS sensor.
Exhaust System Checks Check exhaust system for a possible restriction:
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect muffler for signs of heat distress or for possible internal failure.
- Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following:
- Engine compression
- Valve timing
- Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check 1. Check ECM grounds for being clean, tight, and in their proper locations.
3. If all procedures have been completed and no malfunction has been found, review and inspect the following items:
- Visually and physically inspect all electrical connections within suspected circuit and/or systems.
- Check scan tool data.
Poor Fuel Economy
DEFINITION: Economy is noticeably lower as shown by refueling records.
2. Check air cleaner element (filter) for dirt or restriction.
3. Visually (Physically) check vacuum hoses for splits, kinks, and proper connections.
4. Check operator driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are tires at correct air pressure?
- Are excessively heavy loads being carried?
- Is there often rapid acceleration?
5. Suggest to owner to fill fuel tank and recheck fuel economy.
6. Suggest a different operator use equipment and record results.
Fuel System Checks 1. Check LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
2. Check fuel system for leakage.
Sensor Checks Check Temperature Manifold Absolute Pressure (TMAP) sensor.
3-140 – JLG Lift – 3121180

Checks Action
Ignition System Checks 1. Verify that the spark plugs are correct for use with LPG (R42LTS)
2. Check spark plugs. Remove and inspect plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
3. Check ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks Check engine thermostat for always being open or for the wrong heat range
Additional Check 1. Check transmission shift pattern. Refer to OEM Transmission Controls section Service Manual.
2. Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: Engine runs unevenly at idle. If severe enough, engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe
enough to stall the engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks 1. Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating.
The sensor will result in a high but false signal voltage (rich exhaust indication). ECM will reduce the amount of fuel deliv-
ered to the engine causing a severe driveability problem.
2. Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
3. Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks 1. Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring
the oxygen sensors will help identify the problem.
2. Check for a sticking mixer air valve.
3. Verify proper operation of the EPR.
4. Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
5. Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
6. Check mixer module assembly for proper installation and connection.
Ignition System Checks 1. Check for proper ignition output voltage using spark tester J26792 or equivalent.
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
4. Check spark plug wires by connecting an ohmmeter to ends of each wire in question. If meter reads over 30,000 ohms,
replace wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
1. Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
2.Check ECM grounds for being clean, tight, and in their proper locations.
3. Check battery cables and ground straps. They should be clean and secure. Erratic voltage may cause faulty sensor
readings resulting in poor idle quality.
3121180 – JLG Lift – 3-141

Checks Action
Engine Mechanical Check Check engine for the following:
- Broken motor mounts.
- Improper valve timing.
- Low compression.
- Bent pushrods.
- Worn rocker arms.
- Broken or weak valve springs.
Surges/Chuggles
DEFINITION: Engine has a power variation under a steady throttle or cruise. Vehicle feels as if it speeds up and slows down with no change in accelerator pedal.
Sensor Checks Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks 1. Check Rich or Lean symptom that causes condition. Drive vehicle at speed of complaint. Monitoring oxygen sensors
will help identify problem.
2. Check fuel pressure while condition exists. Refer to LPG Fuel System Diagnosis.
3. Verify proper fuel control solenoid operation.
4. Verify LPG manual shut-off valve is fully open.
5. Check in-line fuel filter for restrictions.
Ignition System Checks 1. Check proper ignition output voltage using spark tester J26792 or equivalent.
2. Verify spark plugs are correct for use with LPG (R42LTS).
- Wet plugs.
- Cracks.
- Wear.
- Improper gap.
- Heavy deposits.
4. Check Crankshaft Position (CKP) sensor.
Additional Check 1. Check ECM grounds clean, tight, and in proper locations.
3. Check vacuum hoses for kinks or leaks.
4. Check transmission.
3-142 – JLG Lift – 3121180

Table 3-16. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

16 Crank Never Synced at Start 636 8
91 Fuel Pump Low Voltage 94 4
92 Fuel Pump High Voltage 94 3
107 MAP Low Voltage 106 4
108 MAP High Pressure 106 16
111 IAT Higher Than Expected 1 105 15
112 IAT Low Voltage 105 4
113 IAT High Voltage 105 3
116 ECT Higher Than Expected 1 110 15
117 ECT Low Voltage 110 4
118 ECT High Voltage 110 3
121 TPS 1 Lower Than TPS 2 51 1
122 TPS 1 Signal Voltage Low 51 4
123 TPS 1 Signal Voltage High 51 3
127 IAT Higher Than Expected 2 105 0
129 BP Low Pressure 108 1
134 EGO 1 Open/Inactive 724 10
154 EGO 2 Open/Inactive 520208 10
171 Adaptive Learn High Gasoline 520200 0
172 Adaptive Learn Low Gasoline 520200 1
182 Fuel Temp Gasoline Low Voltage 174 4
183 Fuel Temp Gasoline High Voltage 174 3
187 Fuel Temp LPG Low Voltage 520240 4
188 Fuel Temp LPG High Voltage 520240 3
217 ECT Higher Than Expected 2 110 0
219 Max Govern Speed Override 515 15
221 TPS 2 Signal Voltage Low 51 0
222 TPS 2 Signal Low Voltage 520251 4
223 TPS 2 Signal High Voltage 520251 3
261 Injector Driver 1 Open 651 5
262 Injector Driver 1 Shorted 651 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1
3121180 – JLG Lift – 3-143

Table 3-16. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

562 System Voltage Low 168 17
563 System Voltage High 168 15
601 Flash Checksum Invalid 628 13
604 RAM Failure 630 12
606 COP Failure 629 31
642 External 5V Reference Low 1079 4
643 External 5V Reference High 1079 3
685 Power Relay Open 1485 5
686 Power Relay Shorted 1485 4
687 Power Relay Short to Power 1485 3
1111 Fuel Rev Limit 515 16
1112 Spark Rev Limit 515 0
1151 Closed Loop Multiplier High LPG 520206 0
1152 Closed Loop Multiplier Low LPG 520206 1
1155 Closed Loop Multiplier High Gasoline 520204 0
1156 Closed Loop Multiplier Low Gasoline 520204 1
1161 Adaptive Learn High LPG 520202 0
1162 Adaptive Learn Low LPG 520202 1
1165 LPG Cat Monitor 520213 10
1171 LPG Pressure Higher Than Expected 520260 0
1172 LPG Pressure Lower Than Expected 520260 1
1173 EPR Comm Lost 520260 31
1174 EPR Voltage Supply High 520260 3
1175 EPR Voltage Supply Low 520260 4
1176 EPR Internal Actuator Fault 520260 12
1177 EPR Internal Circuitry Fault 520260 12
1178 EPR Internal Comm Fault 520260 12
1612 RTI 1 loss 629 31
1613 RTI 2 Loss 629 31
1614 RTI 3 Loss 629 31
1615 A/D Loss 629 31
1616 Invalid Interrupt 629 31
1625 Shutdown Request 1384 31
1626 CAN Tx Failure 639 12
1627 CAN Rx Failure 639 12
1628 CAN Address Conflict Failure 639 13
1629 Loss of TSC 1 639 31
2111 Unable to Reach Lower TPS 51 7
2112 Unable to Reach Higher TPS 51
2135 TPS 1/2 Simultaneous Voltages 51 31
2229 BP Pressure High 108 0
3-144 – JLG Lift – 3121180

1. Battery 6. O2 Sensor 11. Gear Pump

2. Coolant Overflow 7. Crankshaft Position Sensor 12. Motor Mount
3. Air Cleaner 8. Oil Drain Valve 13. Start/Aux Power Relays
4. Radiator 9. Muffler 14. Engine Tray Pivot
5. Alternator 10. Piston Pump 15. Auxiliary Pump
Figure 3-92. GM 3.0L Engine - Sheet 1 of 2
3121180 – JLG Lift – 3-145

16. O2 Sensor 21. Oil Filter 26. Mixer

17. Dipstick 22. Water Pump 27. PCV Valve
18. Control Module 23. Coolant Sensor 28. Oil Pressure Switch
19. Starter 24. Pressure Regulator 29. Coil
20. Distributor 25. MAP Sensor 30. Fuel Filter
Figure 3-93. GM 3.0L Engine - Sheet 2 of 2
3-146 – JLG Lift – 3121180

3.21 PERKINS ENGINE GENERAL Engine Oil Level - Check

MAINTENANCE
Replacing the Engine Crankcase Breather HOT OIL AND COMPONENTS CAN CAUSE SEVERE BURNS. DO
NOT ALLOW HOT OIL OR COMPONENTS TO CONTACT SKIN.
NOTE: Perform this maintenance with engine stopped.

KEEP PARTS CLEAN FROM CONTAMINANTS. CONTAMINANTS
MAY CAUSE RAPID WEAR AND SHORTENED COMPONENT LIFE. 1.Maintain oil level between “ADD” mark (Y) and “FULL”
mark (X) on oil level gauge (1). Do not fill crankcase
above “FULL” mark (X).
NOTE: Operating your engine when oil level is above “FULL”

mark could cause your crankshaft to dip into the oil.
Air bubbles created from crankshaft dipping into the
oil reduces the oil's lubricating characteristics and
could result in loss of power.
2. Remove oil filler cap and add oil, if necessary. Clean

oil filler cap and reinstall.
Engine Oil and Filter - Change

1. Screws for the breather cover
2. Breather cover
3. Spring HOT OIL AND COMPONENTS CAN CAUSE SEVERE BURNS. DO
4. Diaphragm and plate NOT ALLOW HOT OIL OR COMPONENTS TO CONTACT SKIN.
5. Cavity
6. Vent hole
Figure 3-94. Crankcase Breather - Perkins
CARE MUST BE TAKEN TO ENSURE FLUIDS ARE CONTAINED
1.Loosen screws (1) and remove breather cover (2) from DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TEST-
valve mechanism cover. ING, ADJUSTING, AND REPAIR OF THE PRODUCT. BE PREPARED
TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE
2. Remove spring (3). Remove diaphragm and plate (4). OPENING ANY COMPARTMENT OR DISASSEMBLING ANY COM-
3. Clean vent hole (6) and cavity (5) in valve mecha- PONENT CONTAINING FLUIDS. DISPOSE ALL FLUIDS ACCORD-
nism cover. ING TO LOCAL REGULATIONS AND MANDATES.
MAKE SURE THAT THE COMPONENTS OF THE BREATHER KEEP ALL PARTS CLEAN OF CONTAMINANTS. CONTAMINANTS
ASSEMBLY ARE INSTALLED CORRECTLY. ENGINE DAMAGE MAY MAY CAUSE RAPID WEAR AND SHORTENED COMPONENT LIFE.
OCCUR IF THE BREATHER ASSEMBLY IS NOT WORKING COR-
RECTLY.
4. Install new diaphragm and plate (4) for breather

assembly into cavity (5) of valve mechanism cover.
5. Install new spring (3).
6. Install breather cover (2) and four screws (1).
Tighten screws.
3121180 – JLG Lift – 3-147

* 2
** 4
* Torque to 10 ft-lb (13.5 Nm)

** Torque to 21 ft-lb (28.5 Nm)
1. Dipstick 5. Oil Drain Valve

2. Crankcase Breather 6. Oil Filter
3. Coolant Sensor 7. Speed Sensor
4. Oil Pressure Sensor 8. Fuel Filter
Figure 3-95. Perkins Engine
3-148 – JLG Lift – 3121180

NOTE: Do not drain oil when engine is cold. As oil cools, Fuel Filter/Water Separator
suspended waste particles settle on bottom of oil
pan and not removed with oil. Drain crankcase with
engine stopped. Drain crankcase with oil warm. This
draining method allows waste particles suspended
in oil to be drained correctly. Failure to follow this
procedure will allow waste particles to recirculate
through engine lubrication system with new oil.
DRAINING ENGINE OIL

Run engine until normal operating temperature is
reached, then stop engine. Turn drain valve knob counter-
clockwise to drain oil. Turn drain valve knob clockwise to
close drain valve after oil has drained.
FILLING ENGINE CRANKCASE
1. Cap
1. Remove oil filler cap. Refer to Operation and Mainte- 2. Locking Ring
nance Manual for more information on lubricant 3. Element
specifications. Fill crankcase with correct amount of 4. Water Separator Bowl
oil. Refer to Operation and Maintenance Manual for 5. Drain
more information on refill capacities.
Figure 3-96. Fuel Filter/Water Separator
UNDERFILLING OR OVERFILLING CRANKCASE WITH OIL CAN

DAMAGE ENGINE. FUEL LEAKED OR SPILLED ONTO HOT SURFACES OR ELECTRI-
CAL COMPONENTS CAN CAUSE A FIRE. TO HELP PREVENT
POSSIBLE INJURY, TURN START SWITCH OFF WHEN CHANGING
FUEL FILTERS OR WATER SEPARATOR ELEMENTS. CLEAN UP
TO PREVENT CRANKSHAFT BEARING DAMAGE, CRANK ENGINE FUEL SPILLS IMMEDIATELY.
WITH THE FUEL OFF. THIS WILL FILL OIL FILTERS BEFORE
STARTING ENGINE. DO NOT CRANK ENGINE FOR MORE THAN 30
SECONDS.
FUEL/WATER SEPARATOR REMOVES WATER FROM FUEL AND
2. Start engine and run at “LOW IDLE” for two minutes. IS NOT A FILTER. NEVER RUN ENGINE WITH SEPARATOR MORE
Perform this procedure to ensure lubrication system THAN HALF FULL OF WATER. ENGINE DAMAGE MAY RESULT.
has oil and oil filters are filled. Inspect oil filter for
leaks. 1. Open drain at bottom of separator. Catch water in a
3. Stop engine and allow oil to drain to sump for a min- suitable container and dispose of properly.
imum of ten minutes. 2. Close drain.
4. Remove oil level gauge and check oil level. Maintain
oil level between “MIN”” and “MAX” marks on oil
level gauge. FUEL/WATER SEPARATOR IS UNDER SUCTION DURING ENGINE
OPERATION. DRAIN VALVE MUST BE SECURELY TIGHTENED TO
PREVENT AIR FROM ENTERING FUEL SYSTEM.
3121180 – JLG Lift – 3-149

Setting Actuator NOTE: During this procedure it’s very important to keep
control linkage pushed against stop.
1. Remove bolt from control linkage
3. Once adjustments are made to align spherical rod

end bearing with control linkage bolt hole, lengthen
actuator linkage by continuing to turn spherical rod
end and threaded rod 2-2½ turns (1-1¼ turns of
spherical rod end and 1-1¼ turns of threaded rod.)
This will provide 1/8" (3 mm) preload.
4. Use a measuring device to ensure preload is

approximately 1/8" (3 mm), then secure actuator
linkage to control linkage with original bolt and nut.
2. With control linkage pushed against idle stop, begin Make sure spherical ball is seated in control linkage
to make adjustments to actuator linkage in to align bolt hole.
bearing of spherical rod end with control linkage bolt
hole. When making linkage adjustments, thread 5. Tighten two nuts on threaded rod of actuator linkage
spherical rod end and threaded rod evenly (Turn heads using two wrenches to prevent binding of
threaded rod for every turn of spherical rod end.) clevis.
3-150 – JLG Lift – 3121180

Speed Sensor Installation 1. Remove radiator and reservoir caps.
NOTE: A new speed sensor comes with two hex nuts.
1. Remove one hex nut from speed sensor and discard

it.
2. Install speed sensor in housing until it contacts fly-
wheel.
2. Fill radiator to top. Allow coolant to settle and add

coolant as necessary to top off radiator.
3. Reinstall radiator cap.
4. Remove plug from adapter and add coolant at this
3. Back off sensor 1/4 to 3/4 turn. Ensure sensor flats location until radiator hose is full of coolant.
are vertical and tighten nut.
3.22 ENGINE RADIATOR FILL PROCEDURE -

PERKINS & CATERPILLAR
SOME ENGINES REQUIRE A SPECIAL RADIATOR FILL PROCE-

DURE DUE TO COOLING SYSTEM CONFIGURATION. FAILURE TO
FOLLOW THIS PROCEDURE CAN DAMAGE ENGINE.
THE FOLLOWING FILL PROCEDURE SHOULD ONLY BE PERFORMED

WHEN ENGINE IS COLD.
ENGINE COOLANT IS UNDER PRESSURE. DO NOT REMOVE RADIA- 5. Using sealant JLG P/N 0100020 (Loctite #567),
TOR CAP WHEN ENGINE IS WARM. install plug back into adapter.
NOTE: If radiator cap is removed at any time after the follow-

ing steps are performed, coolant will flow out
whether engine is cold or hot.
3121180 – JLG Lift – 3-151

6. Remove fill cap and fill coolant recovery reservoir to

cold level line. Put fill cap back on reservoir when
done.
7. Start engine and run it long enough to bring coolant

to operating temperature. Turn off engine.
REMOVING RADIATOR CAP WITH COOLANT HOT AND UNDER PRES-

SURE CAN CAUSE SEVERE INJURIES. ALLOW ENGINE AND COOL-
ING SYSTEM TO COOL BEFORE REMOVING RADIATOR CAP.
8. Make sure coolant reaches hot level line on coolant

recovery reservoir. Add coolant as needed.
IF RADIATOR CAP IS REMOVED AND COOLANT IS LOST,

REPEAT THIS PROCEDURE TO ENSURE COOLING SYSTEM IS
FILLED TO PROPER LEVEL.
3-152 – JLG Lift – 3121180

3.23 DGC DIAGNOSTIC SUPPORT AND Section Layout

TROUBLE CODE DEFINITIONS This section is organized in the following manner:
This section defines diagnostics and recommended trou-
bleshooting procedures associated with EControls, Diesel
Governor Control (DGC), and Engine Control Module
(ECM) used on industrial engines.
DTC XXXX- Diagnostic Condition
Block Diagram of Circuit
External Hardware Input/Output- This identifies the hardware that either sends an input
to the ECM or is driven by and ECM output.
Check Condition- This defines what condition to troubleshoot the fault condition.
Fault Condition(s)- This identifies the condition(s) that set the fault.
Corrective Action(s)- This identifies the RECOMMENED corrective action(s) that the
ECM is generally programmed to perform. In some instances, the calibration
engineer(s) may choose to perform a different action.
Emissions or Non-emissions related fault
Text to identify the circuit of interest and its use for control.
Text to describe t he conditions that cause the fault to set.
DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
3121180 – JLG Lift – 3-153

List of Abbreviations in this Section

AL Adaptive Learn LED Light Emitting Diode
BP Barometric Pressure LPG Liquefied Propane Gas
CAN Controller Area Network MAP Manifold Absolute Pressure
CCP CAN Calibration Protocol MGCP Marine Global Control Platform
CHT Cylinder Head Temperature μP Microprocessor
CL Closed Loop Mfg Manufacture
CNG Compressed Natural Gas MIL Malfunction Indicator Lamp
DBW Drive-By-Wire NG Natural Gas
DGC Diesel Governor Control OBD On-Board Diagnostics
DM Diagnostic Message OEM Original Equipment Manufacture
DMM Digital Multi-Meter (high impedance) PC Personal Computer
DST Diagnostic Scan Tool PCU Powertrain Control Unit
DTC Diagnostic Trouble Code PFI Port Fuel Injection
DVOM Digital Voltage and Ohm Meter (high impedance) PGN Parameter Group Number
ECI EControls Inc. PWM Pulse Width Modulated
ECIPP EControls Inc. Proprietary Protocol RAM Random Access Memory
ECM Engine Control Module RPM Revolutions Per Minute
ECT Engine Coolant Temperature Rx Receive
ECU Engine Control Unit SAE Society of Automotive Engineering
EDIS EControls Display and Interface Software SA Source Address
EGO Exhaust Gas Oxygen Sensor, typically heated SPFI Sequential Port Fuel Injection
EMWT Exhaust Manifold Water Temperature SPN Suspect Parameter Number
EPR Electronic Pressure Regulator Tach Tachometer
ERWT Exhaust Manifold Riser Temperature TBI Throttle Body Injection
ETB Electronic Throttle Body TDC Top Dead Center
ETC Electronic Throttle Control TIP Throttle Inlet Pressure
FDR Flight Data Recorder TPS Throttle Position Sensor
FMI Failure Mode Indicator TSC Torque/Speed Control
FO Firing Order Tx Transmit
FP Fuel Pressure UEGO Universal Exhaust Gas Oxygen Sensor (Wide-Range EGO)
FPP Foot Pedal Position VDC Voltage, Direct Current
FRP Fuel Rail Pressure VR Variable Reluctance
FRT Fuel Rail Temperature Vsw Switched, Ignition Voltage
FSS Fault Snapshot WGP Waste-Gate Pressure
FT Fuel Temperature
GCP Global Control Platform
Heavy-Duty Global Control Platform
HDGCP
(On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
HO2S Heated Oxygen Sensor (same as HEGO)
IAC Idle Air Control
IAT Intake Air Temperature
ICAV Instant Crank Angle Velocity
IVS Idle Validation Switch
Light-Duty Global Control Platform
LDGCP
(Industrial, Smart/Logic Coil)
3-154 – JLG Lift – 3121180

Fault Code Broadcast • Byte 7: Manifold Absolute Pressure

• Byte 8-9: Engine Speed
All diagnostic trouble codes are broadcast through EDIS
for display on a PC. EDIS can acquire the data from the • Byte 10: Engine Load (MAP based estimate)
ECU via CAN using the EControls Inc. Proprietary Proto-
• Byte 11: Engine Coolant Temperature
col (ECIPP). Faults may also be acquired over the CAN
network through CAN J1939-based scan tools or multi- • Byte 14: # of starts since fault was last active
function display units. • Byte 15: Index into FSS_storage table for Fault Snap
Shot retrieval
Diagnostic Trouble Codes
Resetting active and previously active DTCs is handled
Numeric diagnostic trouble codes assigned to faults in through DM11 and DM3, respectively DM1 and DM2 lamp
this manual are cross-referenced to SAE.s “Recom- indicators are assigned to each fault based on the faults
mended Practice for Diagnostic Trouble Code Definitions” diagnostic action as defined in the calibration. Lamps are
(SAE J2012). While these codes are recommended, cus- assigned based on configuration outlined in Table 3-17.
tomers may define their own codes by assigning a new
number to the flash code in the diagnostic calibration. Table 3-17. J1939 Diagnostic Lamp Configuration
This assigns the DTC as displayed in EDIS and flash code
output on the MIL output pin. EDIS may be used to con- ECI DIAGNOSTIC ACTION J1939 LAMP
nect to the DGC ECM via CAN.
MIL MIL
CAN Soft Warning Amber
The DGC supports SAE J1939 CAN based diagnostic
Hard Warning, Low Rev Limit,
support. This includes: Red Stop
Shutdown
• DM1: Active Diagnostic Trouble Codes
Power Derate 1 & 2 Protect
• DM2: Previously Active Diagnostic Trouble Codes
None (use in combination with
• DM3: Diagnostic Data Clear/Reset of Previously Active Forced Idle
other action)
DTCs
• DM4: Freeze Frame Parameters MIL Output
• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup-
Malfunction Indicator Lamp (MIL) output displays fault
ported)
information to the equipment operator. The MIL is always
• DM11: Diagnostic Data Clear/Reset For Active DTCs on (grounded) when the system is in a key-on (Vsw),
engine-off state. This shows the output is functional. If a
• DM12: Emissions-Related Active Diagnostic Trouble
DTC is logged as previously-active (historic), the MIL
Codes
sends a single flash for the “Blink on-time” every “Blink
• DM19: Calibration Information off-time.”
All diagnostic trouble codes broadcast over CAN are SAE
J1939 DM1 and DM2 formatted messages. DGC ECMs
are compliant with J1939 OBD-M, supporting the Diag-
nostic Messages above as well as user indicators and
CAN data defined in the OBD-M protocol. Faults available
for broadcast and their respective SPN/FMI numbers are
dependent on the application and engine calibration.
There are 4 CAN SPN/FMI lists available in the DGC soft-
ware set, contact EControls Inc. for a list of CAN SPN/
FMIs.
Data capture at occurrence of a fault, known in the ECM
as fault snapshot (FSS), is available upon DM4 request.
The following bytes are supported for DM4 if configured in
ECM software:
• Byte 1: Freeze Frame Length
• Byte 2-6: SPN, FMI, SPN Conversion Method, and
Occurrence
3121180 – JLG Lift – 3-155

Diagnostic Calibration Configuration and Table 2 identifies configuration options and corrective
actions available for configuration of each fault.
Corrective Actions
The desired action is set by OEM calibration engineers.
Each fault within the DGC is capable of being uniquely
configured in the engines diagnostic calibration to cause
one or more corrective actions while a given fault is active.
Table 3-18. Diagnostic Corrective Actions
CORRECTIVE ACTION DESCRIPTION
Enable Enables the fault for fault detection
Shutdown Cause an engine shutdown when fault becomes active
Never Forget Retain fault as historic/previously active until cleared by a technician and does not allow historic fault to be “auto-cleared”
Turn on MIL Turn on MIL output when fault becomes active
CL Disable Disable closed-loop while the fault is active
CL Disable Key- Cyc Disable closed-loop while the fault is active and for the remainder of the key cycle
AL Disable Disable adaptive learn while the fault is active
AL Disable Key-Cyc Disable adaptive learn while the fault is active and for the remainder of the key cycle
Limit TPS to the Power Derate 1 percent set in the diagnostic calibration while the fault is active. The Power Derate 1 TPS
Power Derate 1
percent should be set higher than Power Derate 2 as Power Derate 2 adds a higher level of protection.
Limit TPS to the Power Derate 2 percent set in the diagnostic calibration while the fault is active. If the calibration is set to
Power Derate 2 “Latched for Key-Cycle” Power Derate 2 remains active until engine speed and FPP conditions are satisfied. The Power
Derate 2 TPS percent should be set lower than Power Derate 1 as Power Derate 2 adds a higher level of protection.
Limit RPM to the Low Rev Limit speed set in the diagnostic calibration while the fault is active. If the calibration is set to
Low Rev Limit
“Latched for Key-Cycle” Low Rev Limit remains active until engine speed and FPP conditions are satisfied.
Limit RPM to the Forced Idle speed set in the diagnostic calibration while the fault is active and for the remainder of the key
Forced Idle
cycle
Soft Warning Turn on the soft warning output when the fault becomes active
Hard Warning Turn on the hard warning output when the fault becomes active
Run fault detection/checking while the engine is in a key-on, engine-off condition. NOTE: It is recommended that this fea-
Stopped Check
ture only be used for general sensor faults (high/low voltage) and some output drivers
3-156 – JLG Lift – 3121180

Fault/Diagnostic Trouble Code Interaction have been generated at some instance in time that may or
may not be active in real-time. Once a fault has become
All fault and diagnostic information is managed through active, it is immediately logged as historic and a snapshot
the Faults page. Interaction includes viewing fault mes- and flight data log is saved. Figure 3-97. shows an exam-
sages, downloading fault data (fault snapshot and flight ple of the fault page when an active fault has been gener-
data recorder), erasing faults from memory, and defining ated. Notice fault is present in active and historic lists and
variables for fault data logging. the Malfunction Indicator Lamp (MIL) has been illumi-
nated. Figure 3-98. shows an example of the fault page
Faults are separated into two categories, Active and His-
with a historic fault stored in memory.
toric. Active faults are active in real-time and historic faults
Base Fault snapshot

variable definitions
(CAN NOT be altered)
Custom Fault Snapshot

variable definitions (User
Defined)
Base Flight Data

Recorder variable
definitions (CAN
NOT be altered)
Custom Flight Data
Recorder variable
definitions (User Defined)
Figure 3-97. Faults Page with Active Fault Message
3121180 – JLG Lift – 3-157

Figure 3-98. Faults Page with Historic Fault Message
Once an active fault has occurred, two sets of data are FDR information is stored in RAM, therefore this data is
recorded; fault snapshot and flight data recorder. The fault only available if the ECM has not lost battery power. In
snapshot (FSS) is a sample of data taken when the fault addition, if there is a “Dirty Flash Page” in the ECM, FDR
triggered. Variables included in the FSS are defined in the data will not be available. FSS data is stored in EEPROM
Snapshot Base and Snapshot Custom Definition fields and is retained when the ECM loses battery power.
found on the Faults Page. An FSS is saved with each of
Both sets of data are accessed from the Historic Fault
the first eight (8) faults the first time the fault becomes
Information interface and can be saved to a PC upon
active.
retrieval. Base variables for FSS and FDR are generally
Conversely, the flight data recorder (FDR) is a ten-second defined by the OEM to include variables most often refer-
stream of data that includes eight-seconds prior and two- enced during fault diagnosis. Base definitions are not fault
seconds after triggering the fault. An FDR is saved for dependent. Additional variables may be selected for cap-
each of the first two (2) faults for the first time the fault ture during a fault occurrence through a single, left-click of
becomes active. Variables included in the FDR are defined the custom table and selecting desired variables from a
in the Flight Data Base and Flight Data Custom Definition list. An example of custom fault variable definitions is
fields found on the Faults Page. shown in Figure 3-99.
3-158 – JLG Lift – 3121180

Figure 3-99. Custom Fault Variable Interface
Accessing fault information is accomplished through a From this interface, FDR data may be saved to the PC in
double left-click of the fault LED in the historic fault list. text, tab-delimited format with an .fdr file extension. Once
This produces the Historic Fault Information interface saved to PC, FDR data may be reviewed with any graphi-
shown in Figure 3-100. From this interface a user can cal post-processing software capable of handling tab-
interpret a diagnostic trouble code (DTC) message, iden- delimited formatting.
tify whether or not the fault occurred during the current
Fault information may be manually erased using the
key cycle, identify if the fault caused engine shutdown,
“Clear” button functions. Once a “Clear” function has
determine how many key cycles have occurred since fault
been selected, the dialog prompt shown in Figure 3-103.
was last active, clear selected or all historic faults, and
will be displayed. Choosing YES deletes all fault informa-
view snapshot and flight data. Table 3-19 outlines options
tion from the ECM.
displayed in the Historic Fault Information screen. Historic
faults are not overwritten if the same fault becomes active,
storing data from the original active fault.
DBW Diagnostic Test
Figure 3-101. is an example of a fault snapshot after View The DGC engine control module uses a diagnostic test to
Fault Snapshot is selected. Data is presented in two col- verify proper drive-by-wire throttle actuator operation. This
umns; base and custom variables. FSS data may be diagnostic test is software selectable through the EDIS
saved to a PC in text format with an .fss extension when using the ECIPP protocol. The test permits full-authority
retrieved. An FSS saved to a PC may be reviewed in any operation of an electronic throttle via the throttle com-
ASCII based software program. mand input while engine is in “Stopped” state only. The
ECM reverts to normal operation if “Off” state is selected,
Figure 3-102. shows the Flight Data Recorder interface ignition voltage is lost, or engine speed is sensed.
after View Flight Data Recorder is selected. The FDR cap-
tures a ten second (eight seconds prior and two seconds To enable test, go to DBW page of the EDIS. Set “DBW
after generating the fault) strip of data for base and cus- test mode” to “Enabled”. Double-click “TPS Command”
tom variables. FDR data is presented in an interface simi- setting and enter desired DBW throttle actuator position.
lar to the Plot interface for a quick graphical presentation. The throttle actuator should move to position entered. To
disable test, set “DBW test mode” to “Off.”
3121180 – JLG Lift – 3-159

Figure 3-100. Historic Fault Information Interface
Table 3-19. Historic Fault Information Interface Functions
Fault Description Message Box Customized text that references the DTC flash code and describes the fault.
Fault During Key Cycle Checkbox Informs that the fault occurred during the current key-on event.
Fault Caused Engine Shutdown Checkbox Informs that the fault caused the engine to shutdown.
Key Cycles Since Fault Active Indicator Displays the amount of key-on events since the fault was last active.
Clear This Fault Button* Erases the selected historic fault from the ECM.
Clear All Faults Button* Erases all historic faults from the ECM.
View Snap Shot Data Button Retrieves a data “snap shot” from the ECM for variables defined in the base and custom
snapshot variable definition lists. An example of a fault snap shot is shown in Figure 5.
View Flight Data Recorder Data Button Retrieves a 10-second data strip chart (8 seconds prior, 2seconds after fault trigger) from
the ECM for variables defined in the base and custom flight data recorder definition lists. An
example of a fault snap shot is shown in Figure 6.
Close Button Exits the Historic Fault Information interface. DOES NOT cancel or clear any faults.
* Snapshot and flight data recorder data for historic faults is erased after the prompt shown in Figure 3-103. is satisfied
3-160 – JLG Lift – 3121180

Figure 3-101. Snapshot Data Interface
Figure 3-102. Flight Data Recorder Interface
3121180 – JLG Lift – 3-161

Figure 3-103. Clear Faults Prompt
3.24 DIAGNOSTIC TROUBLE CODE FAULT

DESCRIPTIONS
DTC 116- ECT Higher Than Expected Stage 1
• Engine Coolant Temperature Sensor. Diagnostic Aids

• Check Condition-Engine Running. If “ECT High Voltage” fault is also present, follow trouble-
• Fault Condition-Engine Coolant Temperature reading shooting procedures for that fault as it may have caused
or estimate greater than stage 1 limit when operating at “ECT Higher Than Expected 1.”
a speed greater than defined in diagnostic calibration. Cooling system with air-to-water heat exchanger (radiator)
• Corrective Action(s): Sound audible warning or illumi- and fan:
nate secondary warning lamp, disable adaptive learn
• Check radiator has a proper amount of ethylene glycol/
fueling correction during active fault. Recommend a
water and is not leaking.
power derate 1/2 and/or a low rev limit to protect
engine from possible damage. • Ensure there is no trapped air in cooling path.
• Non-emissions related fault. • Inspect cooling system (radiator and hoses) for cracks
and connections are leak free.
The Engine Coolant Temperature sensor is a thermistor
(temperature sensitive resistor) located in engine coolant. • Check fan is operating properly.
Some engines use a CHT sensor located in cylinder head • Check thermostat is not stuck closed.
coolant. Some engines use an ECT (Engine Coolant Tem-
perature) sensor located in coolant near the thermostat. If Cooling system with water-to-water heat exchanger:
engine is equipped with a CHT sensor, the ECT value is • Check heat exchanger has proper amount of ethylene
estimated. If equipped with an ECT sensor, the CHT value glycol/water and that the heat exchanger is not leaking.
is estimated. They are used for engine airflow calculation,
ignition timing control, to enable certain features, and for • Ensure there is no trapped air in the cooling path.
engine protection. The ECM provides a voltage divider cir- • Inspect cooling system (radiator and hoses) for cracks
cuit. The sensor reads higher voltage when cold and and connections are leak free.
lower when warm.
• Check raw water pickup is not blocked/restricted by
This fault helps protect engine in the event of over temper- debris and hose is tightly connected.
ature. When coolant exceeds x deg. F and engine RPM
exceeds y RPM for the latch time this fault will set. • Check thermostat is not stuck closed.
• Check raw water pump/impeller is intact and not
restricted.
3-162 – JLG Lift – 3121180

DTC 117- ECT/CHT Low Voltage
• Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor
(temperature sensitive resistor) located in the engine cool-
• Check Condition-Engine Running
ant. Some engines use an ECT sensor that is located in
• Fault Condition-CHT/ECT sensor voltage less than the the coolant near the thermostat. Some engines use a CHT
limit defined in the diagnostic calibration (Cylinder Head Temperature) sensor that is located in the
• Corrective Action(s)- Sound audible warning or illumi- coolant in the cylinder head. If the engine is equipped with
nate secondary warning lamp, disable adaptive learn an ECT sensor then the CHT value is estimated. If
fueling correction during active fault, or any combina- equipped with a CHT sensor then the ECT value is esti-
tion thereof as defined in calibration. Recommend a mated. The ECM provides a voltage divider circuit so that
power derate 1/2 to reduce the possibility of engine when the coolant is cool, the signal reads higher voltage,
damage due to the inability to sense temperature. and lower when warm.
• Non-emissions related fault This fault will set if the signal voltage is less than the limit
defined in the diagnostic calibration anytime the engine is
running. The limit is generally set to 0.10 VDC. The ECM
will use a default value for the CHT/ECT sensor in the
event of this fault.
3121180 – JLG Lift – 3-163

3-164 – JLG Lift – 3121180

DTC 118- ECT/CHT High Voltage
• Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor
• Check Condition-Engine Running
ant. Some engines use an ECT sensor that is located in
• Fault Condition-CHT/ECT sensor voltage higher than the coolant near the thermostat. Some engines use a CHT
the limit defined in the diagnostic calibration (Cylinder Head Temperature) sensor that is located in the
• Corrective Action(s)- Sound audible warning or illumi- coolant in the cylinder head. If the engine is equipped with
nate secondary warning lamp, disable adaptive learn an ECT sensor then the CHT value is estimated. If
fueling correction during active fault, or any combina- equipped with a CHT sensor then the ECT value is esti-
tion thereof as defined in calibration. Recommend a mated. The ECM provides a voltage divider circuit so that
power derate 1/2 to reduce the possibility of engine when the coolant is cool, the signal reads higher voltage,
damage due to the inability to sense temperature. and lower when warm.
• Non-emissions related fault This fault will set if the signal voltage is higher than high
voltage limit as defined in diagnostic calibration anytime
engine is running. The limit is generally set to 4.90 VDC. In
many cases, this condition is caused by the CHT/ECT
sensor being disconnected from the engine harness, an
open-circuit or short-to-power of the CHT/ECT circuit in
the wire harness, or a failure of the sensor. The ECM will
use a default value for the CHT/ECT sensor in the event of
this fault.
3121180 – JLG Lift – 3-165

3-166 – JLG Lift – 3121180

DTC 122- TPS1 Signal Voltage Low
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
+ 1
W
B
D +
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 e
t
x
2
1
E
S
P
T D
5
+
=
s
V
R C
ta
le
iS
m
rx 3
1
E
S
P
T -R
rtn
_
V
5
9
1 M
C
E
h
iT
n
le
E
/S
rw
o
a
tu
c
A lte
ria
o
d
e
F
itn
s
o
P b
k
c
a
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor 1. There are two types of throttle actuators;
• Check Condition-Key On, Engine Off. 1) actuator with analog position feedback
• Fault Condition-TPS1 sensor voltage lower than the and

limit defined in the diagnostic calibration. 2) actuator with digital position feedback.
• Corrective Action(s): Sound audible warning or illumi-
The first type, with analog position feedback, provides an
nate secondary warning lamp, shutdown engine.
analog return signal between 0 and 5 volts that is propor-
• Non-emissions related fault. tional to the throttle actuator position. The second type,
with digital position feedback, provides a serial data signal
In the case of a diesel engine, an actuator controls a fuel
to the ECM with the throttle actuator position voltage level
injection pump, directly affecting the fueling level into the
encoded in the data stream.
cylinders. This may be by direct manipulation of the fuel
injection pump rack or by manipulation of the mechanical This fault sets if TPS1 voltage is lower than the low voltage
governor control level or “throttle arm.” limit as defined in the diagnostic calibration at any operat-
ing condition while the engine is cranking or running. The
In the DGC ECM and EDIS, references to the throttle and
limit is generally set to 4.90 VDC. In many cases, this con-
throttle position sensor refer to these fuel injection pump
dition is caused by the TPS sensor being disconnected
control actuators and their position feedback sensors.
from the engine harness, an open-circuit or short-to-
When the fuel injection pump is electronically controlled it
ground of the TPS circuit in the wire harness, or a failure of
can be used to control the idle stability and limit engine
the sensor. This fault should be configured to trigger an
speed based on operating conditions.
engine shutdown and the engine will not start with this
The Throttle Position Sensor uses either; fault active.
1) a variable resistor and voltage divider circuit
or
2) a non-contact hall-effect sensor to determine throttle
actuator position, and is located within the throttle actuator.
3121180 – JLG Lift – 3-167

3-168 – JLG Lift – 3121180

DTC 123- TPS1 Signal Voltage High
+ 1
W
B
D +
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 e
xt
E
S
P
T D
5
+
=
s
V
R C
a
lS
ri
e 2
1
te
i
m
rx 3
1
E
S
P
T M
C
E
R
-
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A o
lt
ria
e
d
e
F
itn
s
o
P k
c
a
b
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor 1. There are two types of throttle actuators, 1) actuator with
analog position feedback and 2) actuator with digital posi-
• Check Condition-Key On, Engine Off.
tion feedback. The first type, with analog position feed-
• Fault Condition-TPS1 sensor voltage higher than the back, provides an analog return signal between 0 and 5
limit defined in the diagnostic calibration. volts that is proportional to the throttle actuator position.
• Corrective Action(s): Sound audible warning or illumi- The second type, with digital position feedback, provides
nate secondary warning lamp, shutdown engine. a serial data signal to the ECM with the throttle actuator
position voltage level encoded in the data stream.
• Non-emissions related fault.
This fault will set if TPS1 voltage is higher than the limit set
In the case of a diesel engine, an actuator controls a fuel in the diagnostic calibration at any operating condition
injection pump, directly affecting fueling level into the cyl- while the engine is cranking or running. The limit is gener-
inders. This may be by direct manipulation of the fuel ally set to 4.90 VDC. In many cases, this condition is
injection pump rack or by manipulation of the mechanical caused by a short-to-power of the TPS circuit in the wire
governor control level or “throttle arm.” In the DGC ECM harness or a failure of the sensor. This fault should be con-
and EDIS, references to throttle and throttle position sen- figured to trigger an engine shutdown and the engine will
sor refer to these fuel injection pump control actuators not start with this fault active.
and their position feedback sensors. When the fuel injec-
tion pump is electronically controlled it can be used to
control the idle stability and limit engine speed based on
operating conditions.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit
or
2) a non-contact hall-effect sensor to determine throttle
actuator position, and is located within the throttle actuator.
3121180 – JLG Lift – 3-169

3-170 – JLG Lift – 3121180

DTC 217- ECT Higher Than Expected 2
• Engine Coolant Temperature Sensor. Diagnostic Aids

• Check Condition-Engine Running.
If “ECT High Voltage” fault is present, follow troubleshoot-
• Fault Condition-Engine Coolant Temperature reading ing procedures for that fault as it may have caused “ECT
or estimate greater than the stage 2 limit when operat- Higher Than Expected 2.”
ing at a speed greater than defined in the diagnostic
calibration. If cooling system uses an air-to-water heat exchanger
(radiator) and fan:
• Corrective Action(s)- Sound audible warning or illumi-
nate secondary warning lamp, disable adaptive learn • Check radiator has a proper amount of ethylene glycol/
fueling correction during active fault. Recommend a water and is not leaking.
power derate 2 and/or a forced idle or engine shut- • Make sure there is no trapped air in the cooling path.
down to protect engine from possible damage.
• Inspect cooling system (radiator and hoses) for cracks
• Non-emissions related fault and ensure connections are leak free.
The Engine Coolant Temperature sensor is a thermistor • Check fan is operating properly.
• Check thermostat is not stuck closed.
ant. Some engines use a CHT sensor that is located in the
coolant in the cylinder head. Some engines use an ECT If cooling system uses a water-to-water heat exchanger:
(Engine Coolant Temperature) sensor that is located in the • Check heat exchanger has proper amount of ethylene
coolant near the thermostat. If the engine is equipped with glycol/water and heat exchanger is not leaking.
a CHT sensor then the ECT value is estimated. If equipped
with an ECT sensor then the CHT value is estimated. The • Make sure there is no trapped air in the cooling path.
ECM provides a voltage divider circuit so when the sensor • Inspect cooling system (radiator and hoses) for cracks
reading is cool the sensor reads higher voltage, and lower and connections are leak free.
when warm. • Check raw water pickup is not blocked/restricted by
This fault helps protect the engine in the event of over debris and hose is tightly connected.
temperature. When coolant exceeds x deg. F and engine • Check thermostat is not stuck closed.
RPM exceeds y RPM for the latch time this fault will set. • Check raw water pump/impeller is intact and not
restricted.
3121180 – JLG Lift – 3-171

DTC 219- RPM Higher Than Max Allowed

Governed Speed
+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T t
x
e
_
V
5
6
1
+
R
E
S
P
T C
D
5
+
=
s
V
lS
ria
e 2
1
i
m
rx
te 3
-1
R
E
S
P
T M
C
E
rtn
_
V
5
9
1
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
o
i
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Max Govern Speed Override- Crankshaft Position Sen- Diagnostic Aids

sor
NOTE: If any other DTCs are present, diagnose those first.
• Check Condition-Engine Running.
• Ensure no programmed governor speeds exceed limit
• Fault Condition-Engine speed greater than the max
set in diagnostic calibration for Max Gov Override
governor override speed as defined in the diagnostic
Speed
calibration.
• Check mechanical operation of the throttle actuator
• Corrective Action(s): Sound audible warning or illumi-
nate secondary warning lamp, reduce throttle to limit
speed. Recommend closed loop and adaptive learn
fueling correction remains active during fault.
• Non-emissions related fault
This fault sets anytime engine RPM exceeds limit set in
diagnostic calibration for latch time or more. This speed
overrides any higher max governor speeds programmed
by the user. This fault is designed to help prevent engine
or equipment damage.
Throttle lowers to govern engine to speed set in diagnos-
tic calibration.
DTC 219- RPM Higher Than Max Allowed Governed
Speed (continued).
3-172 – JLG Lift – 3121180

DTC 336- Crank Signal Input Noise
• Crankshaft Position sensor. Determination of crankshaft position and speed is neces-

sary to properly activate the ignition, fuel injection, and
• Check Condition- Key On, Engine On.
throttle governing systems for precise engine control.
• Fault Condition- Electrical noise or irregular crank pat-
tern detected causing x number of crank resynchroni- The ECM must see a valid crankshaft position signal while
zation events as defined in diagnostic calibration. running. If no signal is present, the signal amplitude is too
high (due to improper air gap with respect to trigger
• Corrective Action(s)- Illuminate MIL and/or sound audi- wheel), or an irregular crank pattern is detected causing
ble warning or illuminate secondary warning lamp and the ECM to resynchronize x times for y ms or longer as
disable adaptive fueling correction for remainder of defined in the diagnostic calibration, this fault will set.
key-cycle. Irregular crank patterns can be detected by the ECM due
• Emissions related fault to electrical noise, poor machining of trigger wheel, or trig-
ger wheel runout and/or gear lash.
The crankshaft position sensor is a magnetic sensor (vari-
able reluctant/magnetic pick-up or Hall effect) installed in Ensure crank circuit used with VR/magnetic pick-up sen-
the engine block adjacent to a “coded” trigger wheel sors are properly twisted.
located on the crankshaft. The sensor-trigger wheel com-
bination determines crankshaft position (with respect to
TDC cylinder #1 compression) and the rotational engine
speed.
3121180 – JLG Lift – 3-173

• Key On, Engine Running

• System Mode= “Running”
Operate engine at condition

that set fault based on fault
snapshot
Yes Is crank sensor a VR/ No Check wiring and electrical connections

Does DTC 336 reset ?
magnetic pick-up? between crankshaft position sensor and ECM
No Yes
No
Is the wiring OK? Repair wireharness
Intermittent fault
Yes
Faulty wireharness No Is wiring between sensor
(twist circuit) and ECM properly twisted?
• Poor system ground
• Bad crankshaft position sensor
• Bad ECM
Yes
Yes
Increase the air gap between Does fault only occur at
sensor and trigger wheel high operating speeds?
No
Check wiring and electrical connections

between crankshaft position sensor and ECM
No
Repair wireharness Is the wiring OK?
Yes
• Poor system ground

• Bad crankshaft position sensor
• Bad ECM
3-174 – JLG Lift – 3121180

DTC 337- Loss of Crank Input Signal
• Crankshaft Position sensor. Diagnostic Aids

• Check Condition- Key On, Engine On. • Check crankshaft position sensor is securely con-
• Fault Condition- Loss of crankshaft position signal nected to harness.
while valid camshaft position signals continue for x • Check crankshaft position sensor is securely installed
number of cam pulses as defined in the diagnostic cal- in engine block.
ibration.
• Check crankshaft position sensor circuit wiring for
• Corrective Action(s)- Illuminate MIL and/or sound audi- open circuit.
ble warning or illuminate secondary warning lamp.
• Emissions related fault.
The crankshaft position sensor is a magnetic sensor (vari-
able reluctant/magnetic pick-up or Hall effect) installed in
the engine block adjacent to a ¡§coded¡¨ trigger wheel
located on the crankshaft. The sensor-trigger wheel com-
bination is used to determine crankshaft position (with
respect to TDC cylinder #1 compression) and rotational
engine speed. Determination of the crankshaft position
and speed is necessary to properly activate the ignition,
fuel injection, and throttle governing systems for precise
engine control.
The ECM must see a valid crankshaft position signal while
running. If no signal is present while x cam pulses con-
tinue, the fault will set. The engine typically stalls or dies
as a result of this fault condition due to lack of crankshaft
speed input, resulting in loss of ignition timing control.
3121180 – JLG Lift – 3-175

DTC 521- Oil Pressure Sender/Switch High

Pressure
• Engine Oil Pressure Additionally for normally-open type oil pressure switches,
a high pressure indication while the engine is off is a
• Check Condition- Key on, Engine on (or Engine off)
symptom of a failed oil pressure switch. The ECM can
• Fault Condition- For sender types, oil pressure higher monitor oil pressure indication when the engine is
than x psia while engine speed is greater that y RPM. stopped for this failure mode.
For switch types, oil pressure is indicating high when
the engine has been stopped for more than n seconds. For sender types, this fault sets if engine oil pressure is
higher than x psia and engine speed greater than y RPM
• Corrective Action(s)- Illuminate MIL and/or sound audi- as defined in diagnostic calibration.
ble warning or illuminate secondary warning lamp,
possibly configure for power derate 1 or low rev limit For switch types, this fault sets if the engine oil pressure is
indicating high when the engine is stopped for more than
• Non-emissions related fault n seconds. Recommend a power derate and/or low rev
The ECM can be configured to monitor oil pressure limit to help prevent possible engine damage and reduce
through a proportional transducer or through a switch. Oil oil pressure.
pressure monitoring is important to prevent engine dam-
age due to low oil pressure resulting in higher friction and
lack of lubrication. In addition, high oil pressure can be
undesirable because it can cause oil to leak past seals
and rings, can be a result of a restriction in the oil flow
path, or can be a sign of a malfunctioning oiling system.
3-176 – JLG Lift – 3121180

Normally Open Switch
• Key-On, Engine Off

• System Mode= “Stopped”
• Key Off
No • Disconnect harness from Oil Pressure switch
Does DTC 524 • Check continuity through switch to ground.
reset ?
Yes
Intermittent Problem
No • Oil Pressure circuit shorted-to-ground in harness

Is switch closed?
• Faulty ECM
Yes
• Faulty Oil Pressure Switch (short circuit)

• Faulty engine oiling system (verify with
mechanical gauge)
Normally Closed Switch
• Key-On, Engine Off

• System Mode= “Stopped”
• Key Off
No • Disconnect harness from Oil Pressure switch
Does DTC 524 • Check continuity through switch to ground.
reset ?
Yes
No • Oil Pressure circuit shorted-to-ground in harness

Is switch open?
• Faulty ECM
Yes

mechanical gauge)
3121180 – JLG Lift – 3-177

Sensor/Transducer Type
3-178 – JLG Lift – 3121180

DTC 524- Oil Pressure Low
• Engine Oil Pressure. For systems that use a transducer, this fault sets if engine
oil pressure is less than x psia and engine speed is
• Check Condition- Key on, Engine on.
greater than y RPM after engine has been running for z
• Fault Condition- Engine oil pressure lower than seconds as defined in diagnostic calibration. For systems
expected while engine has been running for a mini- that use a switch, this fault can be configured two different
mum amount of time while engine speed is above ways. It may use a normally closed switch or a normally
some limit as defined in the diagnostic calibration. open switch.
• Corrective Action(s)- Illuminate MIL and/or sound audi- If switch is normally open, the fault sets if the circuit
ble warning or illuminate secondary warning lamp, becomes grounded.
generally configured to derate the engine and trigger
an engine shutdown. If switch is normally closed, fault sets if circuit becomes
open.
Go to Faults page in EDIS to determine how the input is
The ECM can be configured to monitor oil pressure configured. (“Open=OK” is normally open and
through a proportional transducer or through a switch. Oil “Ground=OK” is normally closed). The engine should be
pressure monitoring is important to prevent engine dam- configured to derate or force idle and/or shut down in the
age due to low oil pressure resulting in higher friction and event of this fault to prevent possible damage.
lack of lubrication. In addition, high oil pressure can be
undesirable because it can cause oil to leak past seals
and rings, can be a result of a restriction in the oil flow
path, or can be a sign of a malfunctioning oiling system.
3121180 – JLG Lift – 3-179

Normally Open Switch
• Key-On, Engine On
• Key Off
• Disconnect harness from Oil Pressure switch
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
Yes
Does DTC 524
reset ?
Yes • Oil Pressure circuit shorted-to-ground in harness
Does DTC 524
reset? • Faulty ECM
No
No
mechanical gauge)
3-180 – JLG Lift – 3121180

Normally Closed Switch
• Key-On, Engine On
• Key Off
• Disconnect harness from Oil Pressure switch
• Jumper Oil Pressure signal wire to ground
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
• Disconnect wireharness header from ECM

• Carefully remove yellow lock from header
Yes at device output terminal
Does DTC 524 • CAREFULLY check resistance between
reset ? Oil Pressure signal at ECM header and
Does DTC 524 Yes signal at sensor. NOTE: DO NOT
reset? INSERT probe or object into terminals
No as this will cause the terminal to
spread and may no longer make
No contact with ECM pin. Spread pins will
void warranty! Probe on the side of
Intermittent Problem terminal.
• Faulty Oil Pressure Switch (open circuit)
mechanical gauge)
• Faulty connection at sensor Yes Does DMM indicate a

• Faulty ECM resistance < 5.0 ohms?
No
• Faulty harness
(open circuit)
3121180 – JLG Lift – 3-181

Sensor/Transducer Type
3-182 – JLG Lift – 3121180

DTC 562- Battery Voltage (VBat) Low
• System voltage to ECM. Battery voltage powers the ECM and must be within limits
to correctly operate throttle actuator, power supplies, and
• Check Condition- Key on, Engine on.
other powered devices the ECM controls.
• Fault Condition- Battery voltage to ECM less than x
volts while the engine is operating at y RPM or greater This fault sets if the ECM detects system voltage less than
as defined in the diagnostic calibration. x volts while the engine is operating at y RPM as defined
in diagnostic calibration as the alternator should be charg-
• Corrective Action(s)- Illuminate MIL and/or sound audi- ing the system.
ble warning or illuminate secondary warning lamp, dis-
able adaptive fueling correction for remainder of key
cycle.
3121180 – JLG Lift – 3-183

3-184 – JLG Lift – 3121180

DTC 563- Battery Voltage (VBat) High
• System voltage to ECM. Battery voltage powers the ECM and must be within limits
to correctly operate throttle actuator, power supplies, and
• Check Condition-Key on, Engine Cranking or Running.
other powered devices the ECM controls.
• Fault Condition- Battery voltage to ECM greater than x
volts while the engine is running as defined in the diag- This fault sets if the ECM detects system voltage greater
nostic calibration. than x volts while engine is running or cranking as defined
in diagnostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audi-
ble warning or illuminate secondary warning lamp, dis-
able adaptive fueling correction for remainder of key
cycle.
3121180 – JLG Lift – 3-185

3-186 – JLG Lift – 3121180

DTC 601- Microprocessor Failure - FLASH
• Engine Control Module- Flash Memory. The ECM has checks that must be satisfied each time an
instruction is executed. Several different things can hap-
• Check Condition- Key on.
pen within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error.
If this fault sets, the ECM will reset itself and log the code.
• Corrective Action(s)- Illuminate MIL and/or sound audi- The fault should be configured to never forget and will not
ble warning or illuminate secondary warning lamp, dis- self-erase and will not clear until a technician performs
able adaptive fueling correction for remainder of key diagnostics and manually clears the code. This fault
cycle, recommend power derate 2 and low rev limit to should be configured to set a power derate 2 and low rev
reduce possible engine damage and/or overspeed limit to reduce possible engine damage and reduce possi-
condition. bility of an overspeed condition. A fault of flash memory
• Non-emissions related fault. can occur for any calibration variable set and thus could
cause undesirable operation.
3121180 – JLG Lift – 3-187

3-188 – JLG Lift – 3121180

DTC 604- Microprocessor Failure - RAM
• Engine Control Module- Random Access Memory. Random Access Memory is located in the microprocessor
and can be read or written at any time. Data stored in RAM
include DTCs (when fault configuration is set to “Battery
• Fault Condition- Internal ECM microprocessor memory Power Retained"), adaptive fuel learn tables, octane adap-
access failure. tation table, misfire adaptation tables, and closed loop fuel
• Corrective Action(s)- Illuminate MIL and/or sound audi- multipliers. The ECM has checks that must be satisfied
ble warning or illuminate secondary warning lamp, dis- each time an instruction is executed.
able adaptive fueling correction for remainder of key This fault sets if the ECM detects a problem accessing or
cycle, recommend power derate 2 and low rev limit to writing information to RAM and should be configured to
reduce possible engine damage and/or overspeed set a power derate 2 and low rev limit to reduce possible
condition. engine damage and reduce possibility of an overspeed
• Non-emissions related fault condition. If this fault sets, the ECM will reset itself and log
the code. This fault should be erased by a technician after
diagnostics are performed. The fault should be configured
to never forget and will not self-erase.
3121180 – JLG Lift – 3-189

3-190 – JLG Lift – 3121180

DTC 606- Microprocessor Failure - COP
• Engine Control Module. The ECM has checks that must be satisfied each time an
• Fault Condition- Internal microprocessor error.
If this fault sets, the ECM will reset itself and log the code.
• Corrective Action(s) - Illuminate MIL and/or sound The fault should be configured to never forget and will not
audible warning or illuminate secondary warning lamp, self-erase and will not clear until a technician performs
disable adaptive fueling correction for remainder of key diagnostics and manually clears the code. This fault
cycle, recommend power derate 2 and low rev limit to should be configured to set a power derate 2 and low rev
reduce possible engine damage and/or overspeed limit to reduce possible engine damage and reduce possi-
condition. bility of an overspeed condition.
3121180 – JLG Lift – 3-191

3-192 – JLG Lift – 3121180

DTC 642- 5 Volt External Low Voltage

+ 1
W
B
D +
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 te
x
2
1
E
S
P
T R
D
5
+
=
s
V C
ta
le
iS
m
rx 3
1
E
S
P
T R
-
rtn
_
V
5
9
1 M
C
E
h
iT
n
le
E
/S
rw
o
a
tu
c
A e
o
lt
ria
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Engine Control Module. Diagnostic Aids

• Check Condition- Key on. • Measure ECM 5-volt output while cycling key on with
• Fault Condition- ECM 5-volt output is below the accept- engine stopped. Verify output is lower than fault thresh-
able limit. olds configured in diagnostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audi- • Inspect 5-Volt output circuit in wire harness and look
ble warning or illuminate secondary warning lamp. for shorts to ground or other harness circuits.
• Non-emissions related fault. • Disconnect each device powered by the ECM 5-volt
output one-at-a-time. Powered devices may include
The ECM supplies 5-volt power to sensors, switches, and throttle actuator, smart sensors, smart actuators, etc.
actuators external to the ECM. By supplying the power to After disconnecting device, observe system fault and
these devices, the ECM can accurately measure their out- determine if fault has cleared. If fault clears, trouble-
put relative to its own ground reference. The ECM can shoot disconnected device for failures.
also control when the devices are active and put the
devices in a low or no power state based on the current • With all 5-volt powered devices disconnected, look for
operating condition of the engine or vehicle. a change in fault state and measure ECM 5-volt output,
and verify it is within acceptable limits.
If this fault sets, something other than the ECM is drawing
ECM 5-volt power output below an acceptable threshold.
This may be due to a short in wire harness, malfunctioning
device, or ECM power output circuitry failure.
3121180 – JLG Lift – 3-193

DTC 643- 5 Volt External High Voltage

+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T t
x
e
_
V
5
6
1
2
1
+
R
E
S
P
T C
D
5
+
=
s
V
lte
iS
m
rx
a 3
-1
R
E
S
P
T
rtn
_
V
5
9
1 M
C
E
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
o
i
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Engine Control Module. Diagnostic Aids

• Check Condition- Key on. • Measure 5-volt ECM output while cycling key on and
• Fault Condition- ECM 5-volt output is above the engine stopped. Verify output is lower than fault thresh-
acceptable limit. olds configured in diagnostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audi- • Inspect 5-Volt output circuit in wire harness and look
ble warning or illuminate secondary warning lamp. for shorts to ground or other harness circuits.
• Non-emissions related fault. • Disconnect each device powered by the ECM 5-volt
output one-at-a-time. Powered devices may include
The ECM supplies 5-volt power to sensors, switches, and the throttle actuator, smart sensors, smart actuators,
actuators external to the ECM. By supplying the power to etc. After disconnecting device, observe system fault
these devices, the ECM can accurately measure their out- and determine if fault has cleared. If fault clears, trou-
put relative to its own ground reference. The ECM can bleshoot disconnected device for failures.
also control when devices are active and put devices in a
low or no power state based on current operating condi- • With all 5-volt powered devices disconnected, look for a
tion of engine or vehicle. change in fault state, measure the ECM 5-volt output
and verify it is within acceptable limits.
If this fault sets, something other than the ECM is drawing
the 5-volt power output of the ECM above an acceptable
threshold. This may be due to a short in the wire harness,
malfunctioning device, or failure of the ECM power output
circuitry.
3-194 – JLG Lift – 3121180

DTC 1612- Microprocessor Failure - RTI 1
• Fault Condition- Internal microprocessor error. The ECM will reset itself in the event this fault is set, and
• MIL- On until code is cleared by technician. the MIL will be on until the code is cleared. This fault
should be erased after diagnosis by removing battery
• Adaptive- Disabled for the remainder of the key-on power. It will not self-erase.
cycle.
During this active fault, Power Derate (level 2) is enforced
• Closed Loop- Enabled. and maximum throttle position is 20%. This is enforced
• Power Derate (level 2 until fault is cleared manually). until fault is manually cleared.
• Engine Control Module The ECM has checks that must be satisfied each time an
• Check Condition- Key on
• Fault Condition- Internal microprocessor error The ECM will reset itself in the event this fault is set, and
• MIL- On until code is cleared by technician the MIL will be on until the code is cleared. This fault
cycle
During this active fault, Power Derate (level 2) will be
• Closed Loop- Enabled enforced. When this is enforced, maximum throttle posi-
• Power Derate (level 2 until fault is cleared manually) tion will be 20%. This is enforced until the fault is manually
cleared.
3121180 – JLG Lift – 3-195

SFC 555- RTI 2 Loss
Key On - Engine Running

System Data Mode
Check all power and

Clear System Fault
ground circuits to ECM
Does SFC 555 reset Yes

with engine idling?
Yes Replace ECM with known
Are all circuits ok?
good part and retest
No
No
Fault is intermittent
Repair wiring to
ECM and retest
3-196 – JLG Lift – 3121180

instruction is executed. Several different things happen
within the microprocessor that causes this fault. The ECM
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and MIL will be
• MIL- On until code is cleared by technician on until the code is cleared. This fault should be erased
after diagnosis by removing battery power. It will not self-
• Adaptive- Disabled for the remainder of the key-on erase.
cycle
• Power Derate (level 2 until fault is cleared manually) tion will be 20%. This is enforced until the fault is manually
cleared.
3121180 – JLG Lift – 3-197

SFC 556- RTI 3 Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 556 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3-198 – JLG Lift – 3121180

DTC 1615- Microprocessor Failure - A/D
• Fault Condition- Internal microprocessor error. The ECM will reset itself in the event this fault is set, and
• MIL- On until code is cleared by technician. the MIL will be on until the code is cleared. This fault
cycle.
• Closed Loop- Enabled. enforced. When this is enforced, maximum throttle posi-
• Power Derate (level 2 until fault is cleared manually). tion will be 20%. This is enforced until the fault is manually
cleared.
3121180 – JLG Lift – 3-199

SFC 513- A/D Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 513 reset

with engine idling?
Yes
Replace ECM with known
No
No
Repair wiring to
ECM and retest
3-200 – JLG Lift – 3121180

DTC 1616- Microprocessor Failure -

interrupt
• Fault Condition- Internal microprocessor error The ECM will reset itself in the event this fault is set, and
• MIL- On until code is cleared by technician the MIL will be on until the code is cleared. This fault
cycle
• Power Derate (level 2 until fault is cleared manually) tion will be 20%. This is enforced until fault is manually
cleared.
3121180 – JLG Lift – 3-201

SFC 512- Invalid Interrupt

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 512 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3-202 – JLG Lift – 3121180

DTC 1625- CAN J1939 Shutdown Request
• Controller Area Network Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running • ECM has shutdown engine upon command by an
• Fault Condition- ECM has received shutdown message external controller. This is requested and expected
from another CAN device and is shutdown on request. behavior.
• Corrective Action(s)- Illuminate MIL, sound audible
warning or illuminate secondary warning lamp
In some situations, external controllers may send a
request to the ECM to shutdown engine operation and
stop the engine. This request may be sent in response to
a safety related condition in the vehicle.
This fault sets if the ECM receives a J1939 shutdown request
via the CAN interface. This is the expected behavior.
3121180 – JLG Lift – 3-203

DTC 1626- CAN J1939 Transmit (Tx) Fault
• Controller Area Network. Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running. • Verify all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver transmit error grounded
counts greater than the limit defined in the diagnostic • Verify the CAN network is properly terminated
calibration (must be < 125 failures).
• Check CAN wire routing with respect to noise sources
• Corrective Action(s)- Illuminate MIL, sound audible (ignition coils, spark plug coil wires, etc.) and shield if
warning or illuminate secondary warning lamp. necessary
• Non-emissions related fault. • Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communica-
tion network used to transmit and receive data between
intelligent devices. Systems that utilize CAN communica-
tion include smart actuators, smart sensors, dash panels
and gauges, and other microcomputers. Each smart sen-
sor, actuator, or controller incorporates a CAN transceiver
that interprets logic level signals on the network and trans-
lates the information into digital data.
This fault will set if CAN communication is enabled and the
ECM transceiver broadcasts a number of packets (as
defined in the diagnostic calibration, must be set to less
than 125 failures) to the network that are not received.
3-204 – JLG Lift – 3121180

DTC 1627- CAN J1939 Receive (Rx) Fault
• Controller Area Network. Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running. • Verify all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver receive error grounded
counts greater than the limit defined in the diagnostic • Verify CAN network is properly terminated
calibration (must be < 125 failures).
• Check CAN wire routing with respect to noise sources
• Corrective Action(s)- Illuminate MIL, sound audible (ignition coils, spark plug coil wires, etc.) and shield if
warning or illuminate secondary warning lamp. necessary
• Non-emissions related fault. • Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communica-
tion network used to transmit and receive data between
intelligent devices. Systems that utilize CAN communica-
tion include smart actuators, smart sensors, dash panels
and gauges, and other microcomputers. Each smart sen-
sor, actuator, or controller incorporates a CAN transceiver
that interprets logic level signals on the network and trans-
lates the information into digital data.
This fault will set if CAN communication is enabled and the
ECM transceiver is expecting to see network traffic and
either does not see traffic (as defined in the diagnostic cal-
ibration, must be set to less than 125 failures).
3121180 – JLG Lift – 3-205

DTC 1628- CAN Address Conflict Failure
• CAN device(s). The Controller Area Network serves as a communication

portal between intelligent devices. These devices may be
• Check Condition- Key On, Engine on.
but are not limited to other engine ECMs (slave), diagnos-
• Fault Condition- two or more devices on the network tic tools, “smart” gauges, “smart” sensors, powertrain
that contain the same SA. control units, vehicle controllers, actuators, etc. The net-
• Corrective Action(s)- Sound audible warning or illumi- work permits several devices to communicate with each
nate secondary warning lamp. other receiving and broadcasting commands as pro-
grammed. This type of network allows devices to be
• Non-emissions related fault. added to an entire system through only two conductors
and permits all other devices to broadcast and receive
commands to and from the device when properly com-
manded.
This fault indicates there are two (2) or more devices on
the network that use the same source address.
3-206 – JLG Lift – 3121180

3121180 – JLG Lift – 3-207

DTC 1629- J1939 TSC1 Message Receipt

Loss
• Controller Area Network. DIAGNOSTIC AIDS

• Check Condition- Key On, Engine Running. • Verify CAN device generating the TSC1 message is
• Fault Condition- ECM is expecting to receive J1939 powered and properly grounded.
TSC1 messages and has not received a message for • Verify CAN network is properly terminated.
more than n seconds (as defined in the diagnostic cali-
bration). • Check CAN wire routing with respect to noise sources
(ignition coils, spark plug coil wires, etc.) and shield if
• Corrective Action(s)- Illuminate MIL, sound audible necessary.
warning or illuminate secondary warning lamp. Govern
engine speed at a forced idle. • Check CAN (+) and (-) wires for short circuits.

J1939 TSC1 may be used to send a commanded (or
desired) engine speed to the ECM. If configured, the ECM
governs engine speed to commanded speed if possible.
When operating in this mode, the ECM expects to receive
TSC1 messages on a regular interval. When this message
is not received, the ECM must operate the engine at a
default idle speed until commanded to do otherwise.
This fault sets if CAN communication is enabled, the
engine is running, and no TSC1 messages are received
over the CAN bus for more than n seconds (as determined
by diagnostic calibration).
3-208 – JLG Lift – 3121180

DTC 1652- TPS1 Loss of Communications

+ 1
W
B
D +
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 te
x
2
1
E
S
P
T R
D
5
+
=
s
V C
ta
le
iS
m
rx 3
1
E
S
P
T R
-
rtn
_
V
5
9
1 M
C
E
h
iT
n
le
E
/S
rw
o
a
tu
c
A e
o
lt
ria
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Actuator (with serial/digital position feedback). Diagnostic Aids

• Check Condition- Key On, Engine Running and/or • Verify throttle actuator 5V supply voltage is present at
Stopped. the actuator.
• Fault Condition- ECM is expecting to receive throttle • Check for a all four TPS feedback wires for short cir-
position information from the throttle actuator and is cuits.
not. • Check TPS SER+ and TPS SER- wire routing with
• Corrective Action(s)- Illuminate MIL, sound audible respect to noise sources (ignition coils, spark plug coil
warning or illuminate secondary warning lamp. Shut- wires, etc.) and shield if necessary.
down engine.
For a throttle actuator with serial/digital position feedback,
the ECM receives a constant data stream from the throttle
actuator. If communication is absent or interrupted, the
ECM can no longer control the throttle position.
This fault will set if the key is on, the throttle actuator is
receiving power, and the ECM is not receiving digital infor-
mation from the actuator.
3121180 – JLG Lift – 3-209

DTC 2111- Unable to Reach Lower TPS

+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T t
x
e
_
V
5
6
1
2
1
+
R
E
S
P
T C
D
5
+
=
s
V
lte
iS
m
rx
a 3
-1
R
E
S
P
T
rtn
_
V
5
9
1 M
C
E
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
o
i
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable
resistor and voltage divider circuit or 2) a non-contact hall-
• Check Condition-Cranking or Running
effect sensor to determine throttle actuator position, and is
• Fault Condition-Throttle command is 20% less than located within the throttle actuator.
throttle position for 200ms or longer
There are two types of throttle actuators, 1) actuator with
• MIL-On during active fault analog position feedback and 2) actuator with digital posi-
• Engine Shut Down tion feedback. The first type, with analog position feed-
back, provides an analog return signal between 0 and 5
On a diesel engine, an actuator controls a fuel injection volts that is proportional to the throttle actuator position.
pump, directly affecting the fueling level into the cylinders. The second type, with digital position feedback, provides
This may be by direct manipulation of the fuel injection a serial data signal to the ECM with the throttle actuator
pump rack or by manipulation of the mechanical governor position voltage level encoded in the data stream.
control level or “throttle arm.” In the DGC ECM and EDIS,
references to the throttle and throttle position sensor refer Fault sets if throttle command is 20% less than actual
to these fuel injection pump control actuators and their throttle position. During active fault, MIL light is on and
position feedback sensors. When the fuel injection pump engine shuts down.
is electronically controlled it can control idle stability and
limit engine speed based on operating conditions.
3-210 – JLG Lift – 3121180

3121180 – JLG Lift – 3-211

DTC 2112- Unable to Reach Higher TPS
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor. The Throttle Position Sensor uses either 1) a variable
resistor and voltage divider circuit or 2) a non-contact hall-
• Check Condition-Cranking or Running.
effect sensor to determine throttle actuator position, and is
• Fault Condition-Throttle command is 20% more than located within the throttle actuator.
actual throttle position.
There are two types of throttle actuators, 1) actuator with
• MIL-On during active fault. analog position feedback and 2) actuator with digital posi-
• Engine Shut Down. tion feedback. The first type, with analog position feed-
back, provides an analog return signal between 0 and 5
On a diesel engine, an actuator controls a fuel injection volts that is proportional to the throttle actuator position.
pump, directly affecting the fueling level into the cylinders. The second type, with digital position feedback, provides
This may be by direct manipulation of the fuel injection a serial data signal to the ECM with the throttle actuator
pump rack or by manipulation of the mechanical governor position voltage level encoded in the data stream.
control level or “throttle arm.” In the DGC ECM and EDIS,
references to throttle and throttle position sensor refer to This fault sets if throttle command is 20% or more than
these fuel injection pump control actuators and their posi- actual throttle position. During this active fault the MIL light
tion feedback sensors. When the fuel injection pump is is on and engine will shut down.
electronically controlled it can control idle stability and
limit engine speed based on operating conditions.
3-212 – JLG Lift – 3121180

DTC 9999- Throttle Actuator Failsafe Spring

Failure
+ 1
W
B
D +
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 te
x
E
S
P
T R
D
5
+
=
s
V C
a
lS
ri
e 2
1
te
i
m
rx 3
1
E
S
P
T M
C
E
R
-
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A e
o
lt
ria
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Actuator Diagnostic Aids

• Check Condition- Key Off, Engine Stopped • Disconnect throttle actuator from wire harness.
• Fault Condition- When key is off (or actuator is unpow- Remove throttle actuator from engine and manually
ered), the ECM is expecting failsafe spring in actuator move it. Verify internal spring forces throttle back to
to return throttle position to near 0%. If throttle does not near 0% position.
reach this position when actuator is powered, a fault is • Inspect throttle arm or fuel rack on fuel pump. Verify it
generated. is not stuck.
• Corrective Action(s)- Illuminate MIL, sound audible
warning or illuminate secondary warning lamp. Govern
engine speed to a forced idle speed.
Throttle actuator has a return spring that causes throttle to
move to a near 0% position when powered off. This
causes engine shutdown following a key off. If ECM
detects throttle position to be above x volts when key is off
(as determined by diagnostic calibration), it will power up
the actuator and attempt to drive it to a zero position. This
should ensure engine is stopped.
Fault sets if throttle does not return to a near 0% position
with key OFF.
3121180 – JLG Lift – 3-213

DTC to SPN/FMI Table
FAULT DTC SET

DESCRIPTION
INDEX SPN FMI
2 DTC 118: ECT voltage high 110 3
3 DTC 117: ECT voltage low 110 4
4 DTC 116: ECT higher than expected stage 1 110 15
9 DTC 563: Vbat voltage high 168 15
10 DTC 562: Vbat voltage low 168 17
11 DTC 643: Sensor supply voltage 1 high 1079 3
12 DTC 642: Sensor supply voltage 1 low 1079 4
13 DTC 123: TPS1 voltage high 51 3
14 DTC 122: TPS1 voltage low 51 4
29 DTC 524: Oil pressure low 100 1
86 DTC 217: ECT higher than expected stage 2 110 0
89 DTC 2112: Unable to reach higher TPS 51 7
90 DTC 2111: Unable to reach lower TPS 51 7
96 DTC 336: CRANK input signal noise 636 2
98 DTC 606: Microprocessor failure - COP 629 31
99 DTC 1612: Microprocessor failure - RTI 1 629 31
102 DTC 1615: Microprocessor failure - A/D 629 31
103 DTC 1616: Microprocessor failure - Interrupt 629 31
104 DTC 601: Microprocessor failure - FLASH 628 13
105 DTC 604: Microprocessor failure - RAM 630 12
106 DTC 219: RPM higher than max allowed govern speed 515 15
144 DTC 337: Crank signal loss 636 4
145 DTC 1625: J1939 shutdown request 1384 31
146 DTC 1626: CAN-J1939 Tx fault 639 12
147 DTC 1627: CAN-J1939 Rx fault 639 12
175 DTC 1628: J1939 CAN address / engine-number conflict 639 13
188 DTC 521: Oil pressure high 100 0
189 DTC 1652: TPS1 loss of communications 51 9
190 DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault 695 9
191 DTC 1113: Unable to achieve lower RPM 515 31
192 DTC 9999: TPS1 failsafe spring failure 51 7
3-214 – JLG Lift – 3121180

OUTLET PIPE MUST BE CENTERED WITHIN 1/4" (6.35 MM) MINIMUM A

CLEARANCE TO EXHAUST VENTURI AROUND VENTURI’S PERIMETER.
IF EXHAUST PIPE TOUCHES VENTURI, IT WILL MELT THE HOOD. IF
EXHAUST PIPE IS NOT CENTERED, ADJUST MUFFLER OR OUTLET AS
NEEDED FOR NECESSARY CLEARANCE.
D C
A. Exhaust Venturi
B. 1/4" (6.35 mm) minimum clearance all around.
C. 3/4" (19.05 mm) minimum engagement
D. Exhaust Pipe Outlet
Figure 3-104. Exhaust Venturi Adjustment
3121180 – JLG Lift – 3-215

B,C B,C
B,C
B,C
B,C
A. Part Number\Actual Weight Stamping
B. Apply Loctite #271 to Bolt Threads and to Threads in Counterweight.
C. Torque to 400 ft-lb (542 Nm). Typical Four Places.
Figure 3-105. Counterweight
3-216 – JLG Lift – 3121180

SECTION 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE
CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DIS-
CONNECTING LINES TO PREVENT ENTRY OF CONTAMINANTS
DO NOT USE A LIFTING DEVICE TO LIFT BOOMS UNLESS HOLD- INTO SYSTEM.
ING VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO
WILL RESULT IN SEVERE DAMAGE TO BOOM. b. Tag and disconnect hydraulic lines from boom
to control valve. Use a suitable container to
Removal of Boom Assembly retain any residual hydraulic fluid. Cap all
hydraulic lines and ports.
1. Remove platform and platform support as follows: c. Using appropriately rated lifting equipment, sup-
a. Disconnect control console electrical cable. port boom weight along entire length.
b. Tag and disconnect hydraulic lines to rotate cyl- d. Remove bolts and keeper pins from lift cylinder
inders. Cap hydraulic lines and ports. pivot pin. Using a suitable brass drift and ham-
mer, remove pivot pin from lower boom.
c. Use an appropriately rated overhead crane or
suitable lifting device and nylon support straps NOTE: To gain access for removal of pivot pins, it may be
to support the platform/support. necessary to remove ground control box, hydraulic
and fuel tanks, and counterweight.
NOTE: Properly support cylinder when removing retaining
pin from rod end of level cylinder.
e. Remove retaining hardware from level link pivot
pin. Using a suitable brass drift and hammer,
d. Remove bolts and keeper pins from retaining
remove pin from level link and turntable.
pins. Remove retaining pins from platform sup-
port using suitable brass drift and hammer. f. Remove hardware securing lower boom pivot
pin. Using a suitable brass drift and hammer,
2. Remove boom from turntable as follows: remove pin from the turntable.
a. Disconnect wiring harness from ground control g. Using all applicable safety precautions, carefully
harness connector. lift boom assembly clear of turntable and lower
to ground or suitable supported work surface.
Figure 4-1. Location of Components - Boom Removal
3121180 – JLG Lift – 4-1

Disassembly of Main Boom Inspection

1. Loosen jam nuts on aft end of fly boom wear pad 1. Inspect all boom pivot pins for wear, scoring or other
adjustment and loosen adjustments. damage, and tapering or ovality. Replace pins as
needed.
2. Using a portable power source, attach hose to tele-
scope cylinder port block. Using all applicable 2. Inspect lift cylinder pins for wear, scoring or other
safety precautions, activate hydraulic system and damage, and for tapering or ovality. Ensure pin sur-
extend cylinder to gain access to cylinder rod retain- faces are protected prior to installation. Replace pins
ing pin. Shut down hydraulic system. as needed.
3. Carefully disconnect hydraulic hose from retract port 3. Inspect telescope cylinder rod attach pin for wear,
of cylinder. There will be initial weeping of hydraulic scoring or other damage. Replace pin as needed.
fluid which can be caught in a suitable container.
4. Inspect inner diameter of boom pivot bushings for
After initial discharge, there should be no further
scoring, distortion, wear or other damage. Replace
leakage from the retract port.
bushings as needed.
4. Remove hardware securing telescope cylinder to
5. Inspect wear pads for wear.
the fly boom section, then remove pin from fly.
6. Inspect all threaded components for damage such
5. Remove hardware securing telescope cylinder to
as stretching, thread deformation, or twisting.
the base boom section.
Replace as needed.
7. Inspect structural units of boom assembly for bend-
WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SEC- ing, cracking, separation of welds, or other damage.
TIONS. CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST Replace boom sections as needed.
ON POWERTRACK WHICH COULD CAUSE DAMAGE TO POW-
ERTRACK.
6. Using a suitable lifting device, remove telescope cyl-

inder from boom sections.
7. Using a piece of tape, mark length of hoses and
wires from front of fly boom and bottom of base
boom for reassembly.
8. Remove hardware securing front wear pads on base
boom section. Remove wear pads.
9. Remove hardware securing powertrack to aft end of
fly boom section.
10. Using a suitable lifting device, remove fly boom from
boom section.
11. Remove hydraulic lines and electrical cables from
powertrack.
12. Remove hardware securing powertrack to base
boom section. Remove powertrack.
4-2 – JLG Lift – 3121180

Assembly of Main Boom Installation of Boom Assembly

1. Install power track to the attach point on the base 1. Using suitable lifting equipment, position boom
boom section. Secure power track with the attaching assembly on turntable so boom pivot holes in boom
hardware. and turntable are aligned.
2. Install hydraulic lines and electrical cables into 2. Install boom pivot pin, ensuring location of hole in
power track. pivot pin aligns with attach point on upright.
3. Install wear pads to the aft end of the fly section. 3. Using all applicable safety precautions, operate lift-
ing equipment to position boom lift cylinder and
4. Using suitable lifting equipment, slide fly section into
level link so holes in cylinder rod end and level link
the base section until power track attach point aligns
are aligned with one in turntable. Insert cylinder
with holes in side of base section.
pins.
5. Attach power track to aft end of fly boom section.
4. If necessary, gently tap pins into position with a soft
Secure power track with attaching hardware.
headed mallet, ensuring attach holes in pins are
6. Using suitable lifting equipment, slide fly boom sec- aligned with attach holes in boom structure. Secure
tion out to gain access to telescope cylinder attach with hardware.
pin hole.
5. Connect all hosing and wiring.
7. Measure distance between telescope cylinder port
6. Install platform to boom assembly.
block attach point on base boom section and attach
point on fly boom section. 7. Connect all hosing and wiring at platform control
station.
8. Connect a suitable auxiliary hydraulic power source
to telescope cylinder port block. 8. Using all safety precautions, operate machine sys-
tems and extend and retract boom for four or five
9. Extend telescope cylinder the distance of the two
cycles.
attach points.
9. Shut down machine systems and check for leaks.
10. Secure sling and lifting device at telescope cylin-
der’s approximate center of gravity. Lift cylinder to
aft end of boom assembly.
WHEN INSERTING TELESCOPE CYLINDER INTO BOOM, CARE

MUST BE TAKEN NOT TO DAMAGE POWER TRACK ASSEMBLY.
11. Slowly slide telescope cylinder into boom assembly

Align rod end with attach point in fly section. Insert
pin and secure with retaining ring.
12. Align bolt holes at aft end of base boom section with
telescope cylinder port block. Secure telescope cyl-
inder with hardware.
13. Install wear pads at end of base boom section.
Using shims, adjust adjustable wear pads to zero
clearance. Adjust pads alternately side to side, so fly
boom section is centered in base boom section.
14. Retract boom section fully. Using shims, adjust wear
pads at aft end of boom section to zero clearance.
Adjust pads alternately side to side, so fly boom sec-
tion is centered in base boom section.
15. Disconnect auxiliary power source from telescope
cylinder.
3121180 – JLG Lift – 4-3

1. Upper Boom
2. Tower Link
3. Upper Upright
4. Upper Lift Cylinder
5. Upper Tower Boom
6. Tower Link
7. Boom
8. Lower Lift Cylinder
9. Lower Upright
Figure 4-2. Boom Assembly
4-4 – JLG Lift – 3121180

Figure 4-2. Boom Limit Switches - US Manufactured
3121180 – JLG Lift – 4-5

Figure 4-3. Boom Limit Switches - Euro Manufactured
4-6 – JLG Lift – 3121180

Figure 4-4. Main Boom
3121180 – JLG Lift – 4-7

4.2 ROTATOR Assembly and Testing

Wash all parts thoroughly in cleaning solvent and blow
Theory of Operation dry. Coat all sealing and working surfaces with a good
See Figure 4-6., Rotator Assembly - Cutaway grade hydraulic oil. Install seals and bearings in piston
sleeve, piston, shaft, and end cap. Exclusion seal lips (16)
Fluid entering Port P2 under pressure will bear on the pis- face outward, and high pressure seal lips face inward.
ton (4) and force piston sleeve (3) upwards. The left- Place actuator in a vertical position, install piston sleeve
handed spline of piston sleeve (3) will combine with right- (3) in timed relation to housing, applying firm pressure as
handed spline of shaft (2A) and cause rapid counter- new seals and bearings enter housing and become com-
clockwise rotation of shaft and flange (2B) (looking down). pressed by housing chamber.
Fluid entering Port P1 will reverse rotation.
Displacement and torque are identical for clockwise and
counterclockwise rotation. DO NOT MISALIGN SLEEVE TOO MUCH ANY ONE WAY, AS IT
Shaft (2A) is integral with shaft flange (2B) and bearing WILL MAR CYLINDER BORE. TIMING MARKS (SMALL PUNCH
tube (2C). The shaft is supported radially by the large MARKS ON FACE OF EACH GEAR), MUST BE ALIGNED FOR
upper radial bearing (19) and lower radial bearing (18). PROPER SHAFT ORIENTATION. REFER TO FIGURE 4-5., TIMING
Axially, shaft is separated from housing by upper and MARKS.
lower thrust rings (20). End cap (5) is adjusted for axial
clearance and locked in position by cap screws (7).
Disassembly and Inspection

Place on a clean workbench with room to place internal
parts as they are removed. Remove all hydraulic fittings
Loosen cap screws(7) and unscrew locknut (6) and end
cap (5). Shaft is now free to move up and out of engage-
ment with piston sleeve (3). Note orientation between
spline teeth (see Figure II), as this will greatly simplify
actuator timing upon reassembly.
After removing shaft, piston sleeve, and piston assembly
can now be moved down and out of housing. Remove all
seals and bearings from their grooves, except static piston
seals (9) and (11). These seals generally do not require
replacement. Clean all parts thoroughly and inspect for
wear. A small amount of wear in spline teeth has little
effect on actuator strength. New spline sets are manufac-
tured with a backlash of about 0.005" (0.127 mm) per mat-
ing set. After long service, a backlash of about 0.015"
(0.381 mm) per set may still be acceptable in most cases,
depending on required accuracy of application.
Item (1) is the integral housing and ring gear. Check ring
gear for wear and weld damage to the pins. Inspect cylin-
der bore for wear and scratches. Surface finish should be
32 RMS or better; re-hone if necessary. Radial bearings 1. Integral Housing & Ring Gear
(18) and (1 9) and piston bearings (17) have a maximum 2. Shaft
radial clearance of 0.006" (0.152 mm). Clearance in 3. Piston Sleeve
excess of 0.008" (0.203 mm) requires bearing replace-
ment. Rough and grooved shaft journals require shaft Figure 4-5. Timing Marks
replacement.
4-8 – JLG Lift – 3121180

1. Housing & Ring Gear 5. End Cap 15. O-ring 21. O-ring
2A. Shaft 6. Locknut 16. Exclusion Seals 22. O-ring
2B. Flange 7. Capscrew 17. Piston Bearing P1 Pressure Port
2C. Bearing Tube 9. Piston Seal 18. Radial Bearing P2 Pressure Port
3. Piston Sleeve 11. Piston Seal 19. Radial Bearing
4. Piston 14. O-ring 20. Thrust Bearing
Figure 4-6. Rotator Assembly - Cutaway
3121180 – JLG Lift – 4-9

If actuator is not equipped with grease fittings, coat thrust NOTE: End caps on 60K and larger actuators may need to
bearings (20) with grease before sliding on shaft and end be installed with actuator in a vertical position.
cap.
Shaft is installed by again aligning punched timing marks. End cap (5) is torqued to 60-400 ft-lb (84-560 Nm)
Temporarily taping threaded portion of shaft will help depending on the actuator size, so actuator begins rota-
installation past shaft seals (masking tape works well). tion at approximately 100 psi (6.9 bar) pressure. Shaft
flange cannot be rotated by hand; combined backdrive
Apply anti-seize to threaded and surrounding areas of
efficiency and friction prevent manual rotation. If end cap
end caps.
is torqued too high, actuator may require as much as 300
psi (20.7 bar) to rotate. If end cap is not torqued high
enough, shaft axial motion and radial backlash will result.
End cap must be secured against shaft by tightening cap
screws (7), or installing axial setscrews, depending on
model. Apply hydraulic pressure and check for breakaway
pressure and shaft axial motion.
To test for leakage, pressurize Port P2 to 3000 psi (206.8
bar). No oil should seep from Port P1 or from around end
cap (5). Repeat test by pressurizing Port P1 and check for
leakage out of Port P2, around shaft flange (2B), and from
ring gear pin welds.
4-10 – JLG Lift – 3121180

4.3 ROTARY ACTUATOR (S/N 0300130812 Required Tools

AND 1300006433 TO PRESENT) Basic tools required for assembly and disassembly of the
actuator and their intended functions are as follows:
Theory of Operation
The L20 Series rotary actuator is a simple mechanism that
uses the sliding spline operating concept to convert linear
piston motion into powerful shaft rotation. Each actuator is
composed of a housing with integrated gear teeth (01)
and only two moving parts: the central shaft with inte-
grated bearing tube and mounting flange (02), and the
annular piston sleeve (03). Helical spline teeth machined
on the shaft engage matching splines on inside diameter
of piston. Outside diameter of piston carries a second set
of splines, of opposite hand, which engage with matching
splines in the housing. As hydraulic pressure is applied,
the piston is displaced axially within the housing - similar
to operation of a hydraulic cylinder - while splines cause
the shaft to rotate. When the control valve is closed, oil is
trapped inside actuator, preventing piston movement and
locking shaft in position. 1. Flashlight - helps examine timing marks, component
failure, and overall condition.
2. Felt Marker - match mark timing marks and outline
troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and
wear guides.
6. Pry bar - end cap removal and manual rotation of shaft.
7. Rubber mallet - removal and installation of shaft and
piston sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end
cap (sold with Helac seal kit).
The seal tool is a customized flat-head screwdriver. To
make this tool, heat flat end with a torch and bend to a
slight radius in a vice. Round off sharp edges with a grinder.
Bars indicate starting posi- As fluid pressure is applied,
tio ns of pisto n and shaft. piston is displaced axially
Arrows indicate direction they while helical gearing causes
rotate. Housing with integral piston and shaft to rot at e
ring gear remains stationary. simultaneously.
The double helix design com-
pounds rotation: shaft rota-
tion is about twice that of the
piston.
Shaft is supported radially by large upper radial bearing

and lower radial bearing. Axially, shaft is separated from
housing by upper and lower thrust washers. The end cap
is adjusted for axial clearance and locked in position by
set screws or pins.
3121180 – JLG Lift – 4-11

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-7. Rotary Actuator - Exploded View
4-12 – JLG Lift – 3121180

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-Ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-8. Rotary Actuator - Assembly Drawing
3121180 – JLG Lift – 4-13

Disassembly 4. Install end cap (4) removal tools provided with Helac
seal kit.
1. Remove capscrews (113) over end cap lock pins (109).
2. Using a 1/8" (3.18mm) drill bit, drill hole in center of each 5. Using a metal bar or similar, unscrew end cap (4) by
lock pin to a depth of approximately 3/16" (4.76mm). turning it counter clockwise.
3. Remove lock pins using an ”Easy Out” (#2 shown).

6. Remove end cap (4) and set aside.
If pin will not come out with ”Easy Out”, use 5/16"
drill bit to a depth of 1/2" (12.7mm) and drill out
entire pin.
4-14 – JLG Lift – 3121180

7. Remove stop tube if included. Stop tube is an avail- 9. Use a felt marker to clearly indicate timing marks
able option to limit actuator rotation. between shaft and piston before removing shaft, (2).
This will greatly simplify timing during assembly.
8. Actuator has timing marks for proper engagement.
10. Remove shaft (2). It may be necessary to strike

threaded end of shaft with a rubber mallet.
3121180 – JLG Lift – 4-15

11. Mark housing (1) ring gear in relation to piston O.D. 13. Mark piston and housing with a marker where piston
gear before removing piston (3). There should now gear teeth come out of engagement with housing
be timing marks on housing (1) ring gear, piston (3) gear teeth as shown.
and shaft (2).
14. Remove O-ring (204) and backup ring (207) from

12. Use a rubber mallet and plastic mandrel to prevent end cap (4) and set aside.
damage when removing piston (3).
15. Remove wear guides (302) from end cap (4) and
shaft (2).
4-16 – JLG Lift – 3121180

16. To remove main pressure seals (205), it is easiest to 19. Remove piston O.D. seal (202).
cut them using a sharp razor blade being careful not
to damage the seal groove.
20. Remove piston I.D. seal (200).
17. Remove thrust washers (304), from end cap (4) and
shaft (2).
18. Remove wiper seal (304.1) from groove in end cap

(4) and shaft (2).
3121180 – JLG Lift – 4-17

Inspection 3. Inspect wear guide condition and measure thick-

ness (not less than 0.123" or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air before inspecting. Carefully inspect all
critical areas for any surface finish abnormalities:
Seal grooves, bearing grooves, thrust surfaces, rod
surface, housing bore and gear teeth.
Assembly
1. Gather all components and tools to one location
before reassembly. Use cut-away drawing to refer-
ence seal orientations.
2. Inspect thrust washers (304) for rough or worn
edges and surfaces. Measure it’s thickness to make
sure it is within specifications (Not less than 0.092"
or 2.34 mm).
4-18 – JLG Lift – 3121180

2. Install thrust washer (304) on shaft (2) and end cap (4). 5. Install wear guide (302) on end cap (4) and shaft (2).
6. Install inner T-seal (200) in piston (3) using a circular

3. Install wiper seal (304.1/green 0-ring) in groove on
motion.
shaft (2) and end cap (4) around outside edge of
thrust washer (304). 7. Install outer T-seal (202) by stretching it around
groove in a circular motion. Each T-seal has 2 back-
up rings (see drawing for orientation).
4. Use seal tool in a circular motion to install main pres-

sure seal (205) on shaft (2) and end cap (4).
8. Beginning with inner seal (200) insert one end of
backup ring in lower groove and feed the rest in
using a circular motion. Make sure wedged ends
overlap correctly.
3121180 – JLG Lift – 4-19

9. Repeat for outer seal (202). 12. Using a rubber mallet, tap piston into housing to
point where gear teeth meet.
10. Insert piston (3) into housing (1) as shown, until

outer piston seal (202) is touching inside housing
bore.
11. Looking from angle shown, rotate piston (3) until

marks on piston and housing (1) line up as shown.
4-20 – JLG Lift – 3121180

13. Look from opposite end of housing (1) to see if tim- 15. Looking from the view shown, use existing timing
ing marks are lining up. When they do, tap piston (3) marks to line up gear teeth on shaft (2) with gear
in until gear teeth mesh together. Tap piston into teeth on inside of piston (3). Now tap flange end of
housing until it bottoms out. shaft with a rubber mallet until gear teeth engage.
14. Install shaft (2) into piston (3). Be careful not to dam- 16. Install 2 bolts in threaded holes in flange. Using a
age seals. Do not engage piston gear teeth yet. bar, rotate shaft in a clockwise direction until wear
guides are seated inside housing bore.
17. Install stop tube onto shaft end. Stop tube is an

available option to limit actuator rotation.
3121180 – JLG Lift – 4-21

18. Coat threads on end of shaft with anti-seize grease 21. Tighten end cap (4). In most cases original holes for
to prevent galling. lock pins will line up.
22. Place lock pins (109) provided in Helac seal kit in

19. Install 0-ring (204) and back-up ring (207) in inner
holes with dimple side up. Using a punch, tap lock
seal groove on end cap (4).
pins to bottom of hole.
20. Thread end cap (4) on shaft (2) end. Make sure wear
guide stays in place on end cap as it is threaded in 23. Insert set screws (113) over lock pins. Tighten to 25 in-lb
housing (1). (2.825 Nm).
4-22 – JLG Lift – 3121180

Installing Counterbalance Valve 3. Bolts that come with valve are grade 8 bolts. Install
new bolts with a new valve. Apply Loctite #242 to
Refer to Figure 4-9., Rotator Counterbalance Valve. the shank of three bolts during installation.
1. Clean actuator surface of any contamination and for- 4. Torque 1/4" bolts 110 to 120 in-lb (12.4 to 13.5 Nm).
eign debris including old Loctite. Do not torque over 125 in-lb (14.1 Nm). Torque 5/16"
bolts 140 in-lb (15.8 Nm). Do not torque over 145 in-lb
2. Make sure new valve has O-rings in counterbores of
(16.3 Nm).
valve to seal it to actuator housing.
Figure 4-9. Rotator Counterbalance Valve
3121180 – JLG Lift – 4-23

A,B,D NOTE: Retorque all bolts on rotator if

any rotator bolts are replaced.
C,D
A Torque to 50 ft-lb (68 Nm)

B Loctite #242
C Torque to 480 ft-lb (650 Nm)
D Check torque every 150 hours of operation
E Torque to 85 ft-lb (115 Nm)
Figure 4-10. Platform Support Torque Values
4-24 – JLG Lift – 3121180

SECTION 5 - HYDRAULICS
SECTION 5. HYDRAULICS
5.1 CYLINDER REPAIR -USA
MANUFACTURED ONLY
NOTE: Following are general procedures that apply to all
cylinders on this machine. Procedures that apply to
a specific cylinder will be so noted.
Disassembly
DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A

DIRT FREE WORK AREA OR CONTAMINATION MAY DAMAGE
EQUIPMENT.
1. Connect a suitable auxiliary hydraulic power source Figure 5-2. Cap Screw Removal
to cylinder port block fitting.
NOTE: Steps 6 and 7 apply only to steer cylinder.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. 6. Loosen spanner nut retainer with spanner wrench.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. Remove spanner nut from cylinder barrel.
7. Being careful not to mar rod surface, use a punch or
2. Operate hydraulic power source and extend cylinder.
wooden dowel and hammer to drive rod guide about
Shut down and disconnect power source. Adequately
one inch into cylinder bore. Using a screw driver,
support cylinder rod, if applicable.
carefully push one end of round retaining ring back
3. If applicable, remove cartridge-type holding valve and towards inside of cylinder and then slip screwdriver
fittings from cylinder port block. Discard O-rings. tip under that end. Pull ring out of groove toward
wall mouth. Once one end of retaining ring is free
4. Place cylinder barrel in a suitable holding fixture. Tap from groove, remainder can be easily pried free with
around outside of cylinder head retainer with a suit- fingers or pliers.
able hammer to break thread-locking compound.
8. Attach a suitable pulling device to cylinder rod port

block end or cylinder rod end.
Figure 5-1. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch

for easy realignment. Using an allen wrench, loosen
eight cylinder head retainer cap screws and remove
cap screws from cylinder barrel.
3121180 – JLG Lift – 5-1

8
20
10 19
16 6
13
14
12
18
17
11
1,2,15
4
1684129 C
1. Loctite #242 6. Barrel 11. Washer Ring 16. T-Seal

2. Locking Primer 7. Rod/Piston 12. Backup Ring 17. Wiper Seal
3. Bushing 8. O-Ring Plug 13. Wear Ring 18. Rod Seal
4. Bushing 9. Not Used 14. O-Ring 19. Bleeder Valve
5. Head 10. Wear Ring 15. Bolt 20. Counterbalance Valve
Figure 5-3. Axle Lockout Cylinder - USA Built Machines Prior to S/N
03000107512
5-2 – JLG Lift – 3121180

17
14
1
17
14
16
5 10
7
11
6 9
24
20
19
13
25
22
12
17
1684243 E
1. Barrel 6. Locknut 11. O-Ring 16. Bleeder 21. O-Ring

2. Rod 7. Retaining Ring 12. Backup Ring 17. Bearing 22. O-Ring
3. Not Used 8. Not Used 13. O-Ring 18. Not Used 23. Not Used
4. Head 9. Wiper 14. Valve Cartridge 19. O-Ring 24. Wear Ring
5. Piston 10. Seal 15. Not Used 20. Seal 25. Retaining Ring
Figure 5-4. Axle Lockout Cylinder - Belgium Built Machines Prior to S/N 1300003222
3121180 – JLG Lift – 5-3

CYLINDER ROD CAN SLIDE OUT OF CYLINDER

IF BLEEDER SCREW IS LOOSENED.
6
1684465 B
1. Barrel 6. Wiper
2. Rod 7. Rod Seal
3. Plug 8. Bleeder
4. Pilot Piston 9. Valve Cartridge
5. Wear Ring
Figure 5-5. Axle Lockout Cylinder - USA Built Machines 0300107512

to Present & Belgium Built Machines 1300003222 to Present
5-4 – JLG Lift – 3121180

6
26
8
6 10
27
5 12
18
13
20
24
13 25
15
16
19
23
17
7
2,3,22
14
1,2,21
9
6
6
1684165 A
1. Loctite #242 6. Composite Bushing 11. Not Used 16. Wear Ring 21. Bolt 26. Valve Cartridge
2. Locking Primer 7. Head 12. Piston 17. Backup Ring 22. Wiper 27. Valve Cartridge
3. Loctite RC609 8. Barrel 13. Wear Ring 18. O-Ring 23. Seal
4. Bolt 9. Rod 14. Washer Ring 19. O-Ring 24. T-Seal
5. Tapered Bushing 10. O-Ring Plug 15. Backup Ring 20. Setscrew 25. Spacer Tube
Figure 5-6. Platform Level Assembly (450A)
3121180 – JLG Lift – 5-5

5
21
3
1
22
8
4
12
20
10
20
12
14
15
14
13
16
19
6
9 18
17
1
23
2
1683760 D
1. Loctite #242 6. Head 11. Not Used 16. O-Ring 21. Valve Cartridge
2. Locking Primer #7471 7. Rod 12. Lock Ring 17. Wiper 22. Valve Cartridge
3. Bolt 8. Barrel 13. Wear Ring 18. Seal 23. Bolt
4. Tapered Bushing 9. Ring Washer 14. Backup Ring 19. Backup Ring
5. Composite Bushing 10. Piston 15. O-Ring 20. Seal
Figure 5-7. Platform Level Cylinder (450AJ) - USA Built Machines
5-6 – JLG Lift – 3121180

17
8
1
18
21
14
4 15
10
20
12
5
29
13 22
8 1684240 C
1. Barrel 6. Not Used 11. Not Used 16. Not Used 21. Retaining Ring 26. Not Used
2. Rod 7. Not Used 12. O-Ring 17. Valve Cartridge 22. O-Ring 27. Not Used
3. Not Used 8. Bearing 13. Backup Ring 18. Valve Cartridge 23. Not Used 28. Not Used
4. Piston 9. Seal 14. Seal 19. Not Used 24. Not Used 29. Retaining Ring
5. Head 10. O-Ring 15. Wiper 20. O-Ring 25. Not Used
Figure 5-8. Platform Level Cylinder (450AJ) - Belgium Built Machines
3121180 – JLG Lift – 5-7

8
27
13
13
10
6
18
19
25
19
18
5
14
16
20
22
17
9
21 23
3,4,24
12
1,3,26
11
7 1683959 B
1. Loctite #242 6. Tapered Bushing 11. Rod 16. Backup Ring 21. O-Ring 26. Bolt
2. Not Used 7. Bushing 12. Ring Washer 17. Backup Ring 22. O-Ring 27. Valve Cartridge
3. Locking Primer 8. Bushing 13. O-Ring Plug 18. Seal 23. Seal
4. Loctite RC609 9. Bushing 14. Piston 19. Wear Ring 24. Wiper
5. Bolt 10. Barrel 15. Not Used 20. Wear Ring 25. T-Seal
Figure 5-9. Jib Cylinder - USA Built Machines
5-8 – JLG Lift – 3121180

8
1
11
11
29
17
16
15 23
14 14
7 6 19
18
28
20
22
21 31
24
2
9
1684242 B
1. Barrel 7. Piston 12. Not Used 17. Retaining Ring 22. O-Ring 27. Not Used
2. Rod 8. Bearing 13. Not Used 18. Wiper 23. O-Ring 28. O-Ring
3. Not Used 9. Bearing 14. Bushing 19. Seal 24. O-Ring 29. Seal
4. Not Used 10. Not Used 15. Sleeve 20. O-Ring 25. Not Used 30. Not Used
5. Not Used 11. Valve Cartridge 16. Nut 21. Backup Ring 26. Not Used 31. Retaining Ring
6. Head
Figure 5-10. Jib Cylinder - Belgium Built Machines
3121180 – JLG Lift – 5-9

23
1
23
11 10
9
6
20
21 20
13 12
14
13
4
15
7
17
16
5
18
19
3
22
23
23 1684155 B
1684154 B
1. Barrel 6. Hex Nut 11. Setscrew 16. Wear Ring 21. Locking Primer
2. Rod 7. Tube Spacer 12. Setscrew 17. O-Ring 22. Loctite
3. End Cap 8. Not Used 13. Wear Ring 18. Seal 23. Bushing
4. Piston 9. Valve Cartridge 14. Seal 19. Wiper
5. Head 10. O-Ring Plug 15. O-Ring 20. Loctite #242
Figure 5-11. Main Lift Cylinder - USA Built Machines
5-10 – JLG Lift – 3121180

25
11
10 14 19
9
7
20
24
12
26 23
21
8
29
22 27
6
1684244 E
1. Barrel 6. Bearing 11. Seal 16. Not Used 21. O-Ring 26. O-Ring
2. Rod 7. Piston 12. O-Ring 17. Not Used 22. Backup Ring 27. O-Ring
3. Not Used 8. Head 13. Not Used 18. Not Used 23. O-Ring 28. Not Used
4. Not Used 9. Nut 14. Spacer 19. Wear Ring 24. Wiper 29. Retaining Ring
5. Not Used 10. Retaining Ring 15. Not Used 20. Seal 25. Valve Cartridge
Figure 5-12. Main Lift Cylinder - Belgium Built Machines
3121180 – JLG Lift – 5-11

24
6
8
25
24
5
15
23
15
10
18
4
19
13
16
17
11 19
7
1,2,12
21
22
6
1684070 E
1. Loctite #242 6. Bushing 11. Ring Washer 16. Wear Ring 21. Seal
2. Locking Primer 7. Head 12. Bolt 17. Backup Ring 22. Wiper
3. Loctite RC609 8. Barrel 13. Tube Spacer 18. Backup Ring 23. T-Seal
4. Bolt 9. Rod 14. Not Used 19. O-Ring 24. Valve Cartridge
5. Tapered Bushing 10. Piston 15. Wear Ring 20. O-Ring 25. O-Ring Plug
Figure 5-13. Tower Lift Cylinder - USA Built Machines
5-12 – JLG Lift – 3121180

6
10
10
16
12
14 19
11
7
20
24
15
23
21
17
8
30
18 26
6 1684239 D
1. Barrel 6. Bearing 11. Nut 16. Seal 21. O-Ring 26. O-Ring
2. Rod 7. Piston 12. Retaining Ring 17. O-Ring 22. Not Used 27. Not Used
3. Not Used 8. Head 13. Not Used 18. Backup Ring 23. O-Ring 28. Not Used
4. Not Used 9. Not Used 14. Spacer 19. Wear Ring 24. Wiper 29. Not Used
5. Not Used 10. Valve Cartridge 15. O-Ring 20. Seal 25. Not Used 30. Retaining Ring
Figure 5-14. Tower Lift Cylinder - Belgium Built Machines
3121180 – JLG Lift – 5-13

10 6
4
5
13
20
12
24
13
15
18
15
25
16
23
2, 3, 22
19
17
7
14
1, 2, 21
9
6
16844170 A
1. Loctite #242 6. Composite Bushing 11. Not Used 16. Wear Ring 21. Bolt
2. Locking Primer 7. Head 12. Piston 17. Backup Ring 22. Wiper
3. Loctite RC609 8. Barrel 13. Wear Ring 18. O-Ring 23. Seal
4. Capscrew 9. Rod 14. Washer Ring 19. O-Ring 24. T-Seal
5. Tapered Bushing 10. O-Ring Plug 15. Backup Ring 20. Setscrew 25. Spacer Tube
Figure 5-15. Master Cylinder (450A)
5-14 – JLG Lift – 3121180

5
9
3
1
2
4
12
20
6
20
12
14
15
14
16
19
13
8
18
7 17
1
2
21
10
5
1683773 E
1. Loctite #242 6. Piston 10. Rod 14. Backup Ring 18. Seal
2. Locking Primer 7. Ring Washer 11. Not Used 15. O-Ring 19. Backup Ring
3. Bolt 8. Head 12. Lock Ring 16. O-Ring 20. Seal
4. Tapered Bushing 9. Barrel 13. Wear Ring 17. Wiper 21. Bolt
5. Composite Bushing
Figure 5-16. Master Cylinder (450AJ) - USA Built Machines
3121180 – JLG Lift – 5-15

8 1
19 18
14
5 15
4
10
12
23
13 21
8
1684241 C
1. Barrel 6. Not Used 11. Not Used 16. Not Used 21. O-Ring
2. Rod 7. Not Used 12. O-Ring 17. Not Used 22. Not Used
3. Not Used 8. Bearing 13. Backup Ring 18. O-Ring 23. Retaining Ring
4. Piston 9. Seal 14. Seal 19. Retaining Ring
5. Head 10. O-Ring 15. Wiper 20. Not Used
Figure 5-17. Master Cylinder(450AJ) - Belgium Built Machines
5-16 – JLG Lift – 3121180

4
7
12
3
8
9
10
10
9
8
3
12
7
4
2
5
11
13 1683614 C
1. Barrel 5. Bolt 9. O-Ring 13. T-Seal

2. Rod 6. Not Used 10. Wear Ring 14. Loctite #242 (Not Shown)
3. Cap 7. Wiper 11. Wear Ring 15. Locking Primer (Not Shown)
4. Ring Washer 8. Backup Ring 12. Seal
Figure 5-18. Steer Cylinder - USA Machines Prior to S/N 87393
3121180 – JLG Lift – 5-17

11
12
3
9
7
10
8
8
10
7
9
3
12
2 11
13 1684412 A
1. Barrel 5. Not Used 9. O-Ring 13. T-Seal

2. Rod 6. Wear Ring 10. O-Ring
3. Cylinder Head 7. Backup Ring 11. Wiper
4. Anti-Seize 8. Wear Ring 12. Seal
Figure 5-19. Steer Cylinder Assembly - USA Machines S/N 87393 to Present
5-18 – JLG Lift – 3121180

7
3
15 14
18
7
14 6
3
12
13
13
18
15
12
10
1684246 B
1. Barrel 7. Seal 13. O-Ring

2. Rod 8. Not Used 14. O-Ring
3. Head 9. Wear Ring 15. O-Ring
4. Not Used 10. Seal 16. Not used
5. Not Used 11. Not Used 17. Not Used
6. Wiper 12. Backup Ring 18. Retaining Ring
Figure 5-20. Steer Cylinder - Belgium Built Machines
3121180 – JLG Lift – 5-19

1684095 E
1684140 E
1. Barrel 6. Valve 11. Retaining Ring 16. O-Ring 21. Not Used
2. Rod 7. Bolt 12. Wear Ring 17. Rod Seal 22. Not Used
3. Piston 8. O-Ring Plug 13. Cap Seal 18. Wiper 23. Wear Pad
4. Head 9. Setscrew 14. O-Ring 19. Loctite #242 24. Bolt
5. Tube Spacer 10. Locknut 15. Wear Ring 20. Not Used 25. Adapter
Figure 5-21. Telescope Cylinder - USA Built Machines
5-20 – JLG Lift – 3121180

18
5
5A
25
6 9
26
8
14
4 16
20
19
13
27
23
1684262 C
1. Barrel 6. Piston 11. Not Used 16. Wiper 21. Not Used 26. Wear Ring
2. Rod 7. Seal 12. Not Used 17. Not Used 22. Not Used 27. Retaining Ring
3. Not Used 8. O-Ring 13. O-Ring 18. Bolt 23. O-Ring
4. Head 9. Spacer 14. Seal 19. O-Ring 24. Not Used
5. Valve Block 10. Not Used 15. Not Used 20. O-Ring 25. Setscrew
Figure 5-22. Telescope Cylinder - Belgium Built Machines
3121180 – JLG Lift – 5-21

USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD,

AND PISTON. PULLING ROD OFF-CENTER CAN DAMAGE PISTON
AND CYLINDER BARREL SURFACES.
9. With barrel clamped securely, apply pressure to rod

pulling device and carefully withdraw complete rod
assembly from cylinder barrel.
Figure 5-24. Tapered Bushing Removal
15. Screw piston CCW by hand and remove piston from

cylinder rod.
16. Remove and discard piston O-rings, seal rings, and
backup rings.
17. Remove piston spacer, if applicable, from rod.
18. Remove rod from holding fixture. Remove cylinder
Figure 5-23. Cylinder Rod Support head gland and retainer plate, if applicable. Discard
O-rings, back-up rings, rod seals, and wiper seals.
10. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston Cleaning and Inspection
as possible. 1. Clean all parts thoroughly in an approved cleaning
NOTE: Step 11 applies only to the steer cylinder. solvent.
2. Inspect cylinder rod for scoring, tapering, ovality, or
11. Loosen and remove nut which attaches piston to other damage. If necessary, dress rod with Scotch
rod, and remove piston. Brite or equivalent. Replace rod if necessary.
12. Loosen and remove cap screw(s), if applicable, 3. Inspect threaded portion of rod for excessive dam-
which attach tapered bushing to piston. age. Dress threads as necessary.
13. Insert cap screw(s) in threaded holes in outer piece 4. Inspect inner surface of cylinder barrel tube for scor-
of tapered bushing. Progressively tighten cap ing or other damage. Check inside diameter for
screw(s) until bushing is loose on piston. tapering or ovality. Replace if necessary.
14. Remove bushing from piston. 5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
8. Inspect seal and O-ring grooves in piston for burrs
and sharp edges. Dress surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace
as necessary.
5-22 – JLG Lift – 3121180

10. Inspect threaded portion of head for damage. Dress Assembly

threads as necessary.
NOTE: Use proper cylinder seal kit for cylinder assembly.
11. Inspect seal and O-ring grooves in head for burrs
See your JLG Parts Manual.
and sharp edges. Dress applicable surfaces as nec-
essary.
Apply a light film of hydraulic oil to all components
12. Inspect cylinder head outside diameter for scoring before assembly.
or other damage and ovality and tapering. Replace
as necessary. 1. A special tool is used to install a new rod seal into
applicable cylinder head gland groove.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod/barrel
must be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing.
NOTE: Install pin into the Gar-Max bearing dry. Lubrication is

not required with nickel plated pins and bearings. Figure 5-26. Rod Seal Installation
ENSURE SEALS ARE INSTALLED PROPERLY WHEN INSTALLING

‘POLY-PAK’ PISTON SEALS. REFER TO WIPER SEAL INSTALLA-
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION CAN CAUSE CYLINDER LEAKAGE AND IMPROPER
CYLINDER OPERATION.
Figure 5-25. Gar-Max Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
3121180 – JLG Lift – 5-23

2. Use a soft mallet to tap a new wiper seal into appli- 6. If applicable, correctly place a new O-ring and back-
cable cylinder head gland groove. Install new wear up rings in the inner piston diameter groove.
ring into applicable cylinder head gland groove.
Figure 5-27. Poly-Pak Piston Seal Installation
Figure 5-30. Piston Seal Kit Installation
7. Using suitable protection, clamp cylinder rod in a

vise or similar holding fixture as close to piston as
possible.
8. Carefully thread the piston on cylinder rod hand
tight, ensuring O-ring and back-up rings are not
damaged or dislodged.
9. Thread piston onto rod until it abuts spacer end and
install tapered bushing.
Figure 5-28. Wiper Seal Installation NOTE: When installing the tapered bushing, piston and mat-
ing end of rod must be free of oil.
3. Place a new O-ring and back-up seal in applicable

outside diameter groove of cylinder head.
WHEN REBUILDING THE MASTER, SLAVE, LIFT, OR TELESCOPE
CYLINDERS, APPLY LOCTITE #242 TO TAPERED BUSHING
BOLTS, THEN TIGHTEN SECURELY. (SEE TABLE 2-1 AND 2-3.
TORQUE SPECIFICATIONS).
10. Install bolts in tapered bushing using loctite #242.

(See Table 2-1 and 2-3. Torque Specifications.)
Figure 5-29. Installation of Head Seal Kit
4. Install washer ring onto rod, carefully install head

gland on rod, ensuring wiper and rod seals are not
damaged or dislodged. Push head along rod to rod
end, as applicable.
5. Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring Figure 5-31. Tapered Bushing Installation
installed inside spacer.
5-24 – JLG Lift – 3121180

11. Remove cylinder rod from holding fixture. Table 5-1. Cylinder Head and Tapered Bushing Torque
Specifications
12. Place new guide locks and seals in applicable out-
side diameter grooves of cylinder piston. (See Fig- Head Torque Tapered Bushing
ure 2-28. Piston Seal Kit Installation.) Value (Wet)
Description Torque Value
13. Position cylinder barrel in a suitable holding fixture. (Wet)
Slave Cylinder 30 ft. lbs. 5 ft. lbs.

(41 Nm) (9 Nm)
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING CYLIN-
DER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF- Master Cylinder 30 ft. lbs. 5 ft. lbs.
CENTER, WHICH CAN DAMAGE PISTON AND CYLINDER BARREL (41 Nm) (9 Nm)
SURFACES.
Jib Cylinder 30 ft. lbs. 5 ft. lbs.
14. With barrel clamped securely, and while adequately (41 Nm) (9 Nm)
supporting rod, insert piston end into barrel cylinder.
Lockout Cylinder 80 ft. lbs. N/A
Ensure piston loading O-ring and seal ring are not
(109 Nm)
damaged or dislodged.
15. Continue pushing rod into barrel until cylinder head Steer Cylinder Piston Nut Torque Specifications
gland can be inserted into barrel cylinder. Steer Cylinder LBS. NM
16. Secure cylinder head gland using washer ring and
150 ft. lbs 204 Nm
socket head bolts. (See Table 2-1 and 2-3. Torque
Specifications.)
Table 5-2. Holding Valve Torque Specifications
Description Torque Value
SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

(204-217 Nm)
Figure 5-32. Rod Assembly Installation
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.
(68-75 Nm)
17. After cylinder has been reassembled, rod should be
pushed all the way in (fully retracted) before reinstal- RACINE - 1 3/8 HEX 1 3/16 - 12 THDS. 75-80 ft. lbs.
lation of any holding valve or valves. (102-109 Nm)
18. If applicable, install cartridge-type holding valve and fit- RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs.
tings in rod port block. Use new O-rings as applicable. (136-149 Nm)
(See Table 2-2. Holding Valve Torque Specifications).
Table 5-1. Cylinder Head and Tapered Bushing Torque

Specifications
Head Torque Tapered Bushing

Description Value (Wet) Torque Value
(Wet)
Lift Cylinder 120 ft. lbs. 9 ft. lbs.

(163 Nm) (12 Nm)
3121180 – JLG Lift – 5-25

5. Clamp mounting flange in a protected jaw vise with

pump shaft facing down.
IF CYLINDER IS TEST PRIOR TO INSTALLATION ON MACHINE,
USE EXTREME CARE TO INSURE OUTER END OF ROD IS SUP- 6. Loosen four metric hex head bolts.
PORTED. USE A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR 7. Remove pump from vise and place on clean work
OTHER MEANS TO SUPPORT OVERHANGING WEIGHT OF bench, remove the four hex head bolts and spacers
EXTENDING ROD. if applicable.
5.2 HYDRAULIC PUMP (GEAR)

Disassembly
NOTE: The following general instructions also apply to mul-
tiple section gear pumps. The only extra parts are the
coupling between drive shafts and center distance
plate which divides the two pump sections. This
repair procedure also applies to ”W” series Gear
Motors.
1. It is very important to work in a clean work area

when repairing hydraulic products. Plug ports and
8. Lift and remove end cover.
wash exterior of pump with a proper cleaning sol-
vent before continuing.
2. Remove port plugs and drain oil from pump.
9. Carefully remove gear housing and place on work

bench. Make sure rear bearing block remains on
drive and idler shafts.
3. Use a permanent marker pen to mark a line across
mounting flange, gear housing and end cover. This
will assure proper reassembly and rotation of pump.
4. Remove key from drive shaft if applicable.
5-26 – JLG Lift – 3121180

10. Remove rear bearing block from drive and idler 13. Remove front bearing block.
shafts.
14. Turn mounting flange over, with shaft seal up, and
11. Remove idler shaft from bearing block. remove retaining ring with proper snap ring pliers.
12. Remove drive shaft from mounting flange. There is 15. Remove oil seal from mounting flange, be careful
no need to protect the shaft seal as it will be not to mar or scratch seal bore.
replaced as a new item.
16. Remove dowel pins from gear housing. Do not lose
pins.
17. Remove seals from both bearing blocks and dis-

card.
3121180 – JLG Lift – 5-27

Inspect Parts For Wear 5. Inspect bearing blocks for excessive wear or scoring
on surfaces in contact with gears. Inspect bearings
1. Clean and dry all parts thoroughly before inspection. for excessive wear or scoring.
It is not necessary to inspect seals. They will be
6. Inspect area inside gear housing. A clean ”wipe” on
placed as new items.
the inside surface of the intake side is normal. There
should not be excessive wear, deep scratches, or
gouges.
2. Check drive shaft spine for twisted or broken teeth,

check keyed drive shaft for broken or chipped key-
way. No marks or grooves on shaft in seal area,
some discoloration of shaft is allowable.
3. Inspect drive gear shaft and idler gear shafts at bearing
points and seal area for rough surfaces and excessive
wear.
4. Inspect gear face for scoring or excessive wear. If

face edge of gear teeth are sharp, they will mill into
the bearing blocks. If wear has occurred, parts are
unusable.
5-28 – JLG Lift – 3121180

General Information
FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT

WITH LITTLE OR NO FLOW AT RATED PRESSURE. RELATIONSHIP
OF MOUNTING FLANGE, BEARING BLOCKS, AND GEAR HOUSING
MUST BE CORRECT.
Reverse Shaft Rotation of Pump

NOTE: Pump is not bi-rotational. Use the following proce-
dure if shaft rotation direction is changed.
Reverse shaft rotation of the ”W” series gear pump by 3. Place front and back bearing blocks on a clean sur-
rotating, as a group, two bearing blocks and gear housing face with E-seal grooves facing up. Apply a light
180° in relationship to remaining parts of pump. This coating of petroleum jelly in the grooves. Coat E-
places pressure port on opposite side of pump from its seal and backup with petroleum jelly. This helps
original position. keep seals in place during reassembly.
Assembly
NOTE: Install new seals when reassembling pump or motor.
Go to page 8 for kit part numbers for W-600, W-900,
and W-1500 pumps and motors.
4. Place E-seals, flat side outward, into grooves in both

bearing blocks. Carefully place backup ring, flat side
outward, in groove made by E-seal and groove in
1. Install new shaft seal in mounting flange with part bearing block. (Note: W900 series pump - In center
lumber side facing outboard. Press seal into seal of backup ring and E-seal there is a notch. Make sure
bore until seal reaches the bottom of bore. Uniform notches line up so backup ring will set flush with E-
pressure must be used to prevent seal misalignment seal). Backup ring in W1500 pump is symmetrical.
or damage.
5. Place mounting flange, with shaft seal side down, on
a clean flat surface.
2. Install retaining ring in groove in seal bore of mount-

ing flange.
3121180 – JLG Lift – 5-29

6. Apply a light coating of petroleum jelly to exposed 11. Install two dowel pins in mounting flange holes or
face of front bearing block. two long dowel pins through gear housing if pump is
a multiple section pump.
7. Insert drive end of drive shaft through bearing block

12. Apply a light coating of petroleum jelly in grooves on
with seal side down and open side of E-seal pointing
both sides of gear housing. Coat new O-rings and
to intake side of pump.
install in grooves.
8. Install seal sleeve over drive shaft. Carefully slide
drive shaft through shaft seal. Remove seal sleeve
from shaft.
13. Gently slide gear housing over rear bearing block

assembly. Slide housing down until it engages the
dowel pins. Press firmly in place with hands, do not
9. Install idler gear shaft in remaining position in bear-
force or use any tool. Check intake port in housing is
ing block. Apply a light coat of clean oil to face of
on same side as open end of E-seal and marked
drive and idler gears.
lines on mounting flange and gear housing are in
alignment.
NOTE: Rear bearing block surface should be slightly below

gear housing face. If bearing block is higher than
rear face of gear housing, E-seal or O-ring have
shifted out of groove. Remove gear housing and
check for proper seal installation.
10. Place rear bearing block over drive and idler gear
shafts with seal side up and open end of E-seal
facing intake side of pump.
5-30 – JLG Lift – 3121180

19. Name plate located on end cover contains build

14. Install two remaining dowel pins in rear of gear date code and model number. Please refer to this
housing, if applicable, and place end cover over information when corresponding with the J.S.
back of pump. Barnes Service Department.
Table 5-3.Hydraulic Pump Bolt Torque Chart
Torque Torque
Values, Black Values, Zinc
Pump Series Thread Size
Oxide End Plated End
Cover Cover
W-600 M 8 x 1.25 18-21 ft.lb. 16-18 ft.lb.

24-30 Nm 21.7-24.4 Nm
W-900 M 10 x 1.5 50-55 ft.lb. 38-43 ft.lb.

68-75 Nm 51.5-58.3 Nm
15. Install four spacers (if applicable) and hex head
bolts through bolt holes in end cover. Hand tighten. W-1500 M 12 x 1.75 80-85 ft.lb. 68-73 ft.lb.
108-115 Nm 92.2-99 Nm
16. Place mounting flange of pump back in protected

jawed vise and alternately torque bolts to torque
specifications in the torque chart. All torque figures
are for ”dry torque” bolts.
17. Remove pump from vise.
18. Place a small amount of clean oil in pump inlet and
rotate drive shaft away from inlet one revolution. If
drive shaft binds, disassemble pump and check for
assembly problems, then reassemble pump.
3121180 – JLG Lift – 5-31

Placing Pump Back Into Service 5.3 VARIABLE PUMP

1. If shop test stand is available, the following proce- Ports and Pressure Gauges
dure for testing rebuilt pumps is recommended:
Proper servicing of pumps and motors requires pressure
a. Mount pump on test stand. Make sure proper be measured and monitored at various points in the
level of clean oil is available in reservoir. Check hydraulic circuit. The Series 42 pump has several loca-
suction line for leaks and obstructions. tions at which to take these measurements. The following
b. Start pump and run for three minutes at zero outlines show locations of various gauge ports. The fol-
pressure. lowing table shows recommended gauge size and fitting
size for each port.
c. Intermittently load pump to 500 P.S.I. for three
minutes.
Table 5-4. Recommended Gauge Size
d. Intermittently load pump to 1000 P.S.I. for three
minutes. Recommended
Gauge
e. Intermittently load pump to 2000 P.S.I. for three Port
Pressure Gauge Size
Fitting
minutes. Name
Measured
PSI Bar
f. Remove pump from test stand and check for
freeness of drive shaft. Check pump for signs of M1 & M2 System 10000 600 9/16-18 ORF
external leakage. Pressure
Ports A & B
2. If shop test stand is not available, the following pro-
cedure for testing rebuilt pumps is recommended: M3 Charge 1000 60 3/4-16 ORF
a. For engine driven pumps, mount pump on Servo
M4 & M5 1000 60 9/16-18 ORF
equipment and run pump at 1/2 engine speed at
zero pressure for three minutes. L1 & L2 Case 500 35 1-1/16-12 ORF
b. Operate control valve and build pressure inter-
S Charge Pump 30 in. Hg Vac. 1 1-1/16-12 ORF
mittently for three minutes.
Inlet Vacuum
c. Increase engine speed to full throttle and build
pressure intermittently for three minutes.
d. Stop engine and check pump for external leaks. NFPE Control
The 3-position FNR control, and electric and hydraulic
non-feedback proportional (NFPE and NFPH) controls are
non-feedback type controls. FNR and NFPE controls con-
sist of pump housing mounted modules. Hydraulic input
for NFPH is received through ports on top of pump [9/16–
18 SAE O-ring fitting].
The non-feedback controls are factory set. Control mod-
ules can be removed to clean ports and change O-rings.
Orifice plugs for the FNR and NFPE are located inside the
servo piston covers. Orifice plugs for the NFPH are
located in the NFPH ports. Orifice plugs may be cleaned
or replaced.
5-32 – JLG Lift – 3121180

Removal and Installation of FNR and NFPE SHIM ADJUSTABLE STYLE
Modules
1. Clean pump and module housings.
2. Remove four screws retaining module to pump housing
(4 mm Int. Hex). Remove module from housing.
3. Remove O-rings from the control ports. Examine
ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).
Removal and Installation of FNR and NFPE

Control Orifices
NOTE: Future models may contain an orifice plate between
module and pump housing. This will take the place 1. Plug 4. Spring T-Seal
of the orifice plugs beneath the servo piston cover. 2. O-Ring 5. Poppet
3. Shims
1. Remove servo piston cover.
Figure 5-33. Shim Adjustable Charge Relief Valve
2. Remove orifice plug (1/8" Int. Hex).
Components
3. Examine orifice and port for cleanliness.
4. Install orifice plug. Torque to 1.5 - 2.5 ft-lb (2.0-3.4 Nm). 1. Remove shim adjustable charge relief valve plug (1" Hex)
from pump housing. Remove O-ring from plug.
Charge Relief Valve
2. Remove spring and poppet from housing.
Charge relief valve may be removed for cleaning and
3. Do not alter shims which may be installed between
installation of new O-rings. The pressure setting may be
spring and valve plug, or interchange parts with
changed. Setting will vary for different charge flows
another valve. Inspect poppet and mating seat in
depending on charge pump size and pump speed. Fac-
housing for damage or foreign material.
tory setting is set relative to case pressure at 1800 rpm.
Actual charge pressure will vary at different speeds. 4. If desired, charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar /
1.25 mm (58 psi / 0.050 in). Effective setting will vary.
To confirm charge relief valve setting, measure

charge pressure (port M3) with pump in stroke.
Charge pressure should level off when relief setting
is reached.
3121180 – JLG Lift – 5-33

1. System Pressure Gauge Port M2
2. System Pressure Port B
3. System Pressure Port A
4. System Pressure Gauge Port M1
5. Servo Pressure Gauge Port M5
6. Case Drain Port L2 (non-feedback)
7. Case Drain Port L2
8. Servo Pressure Gauge Port L4
9. Case Drain Port L1
10. Case Drain Port L1 (non-feedback)
11. Charge Pressure Gauge
12. Charge Pump Inlet Port S
Figure 5-34. Gauge Port Locations
5-34 – JLG Lift – 3121180

Plug/ Torque
#
Fitting lb. ft. Nm
1 Servo Gauge Port N/A N/A
M4
2 11/16 20-35 27-47
3 9/16 70-100 95-135
4 Case Drain Port L1 N/A N/A
5 Charge Pressure N/A N/A
Gauge M3
6 Charge Pump Inlet 85 115
Port S
7 Case Drain Port L2 N/A N/A
8 Port N N/A N/A
9 System Gauge M1 & N/A N/A
M2
10 System Ports A&B 85 115
11 11/16 20-35 27-47
12 9/16 70-100 95-135
13 11/16 20-35 27-47
14 Servo Gauge M5 N/A N/A
15 11/16 20-35 27-47
Figure 5-35. Plugs/Fittings Size & Torque
3121180 – JLG Lift – 5-35

5. Install new O-ring on valve plug. Reinstall poppet, Shaft Seal and Shaft Replacement
spring, and plug (with shims and O-ring) into pump
housing. Torque to 40-100 ft-lb (55-135 Nm).
SCREW ADJUSTABLE STYLE
1. Retaining Ring 2. Seal Carrier Assembly

1. Lock Nut 4. Spring T-Seal
2. O-Ring 5. Poppet Figure 5-37. Shaft Seal Components
3. Plug
Figure 5-36. Screw Adjustable Charge Relief A lip type shaft seal is used in Series 42 pumps. Seal and
Valve Components shaft can be replaced without major unit disassembly.
Replacement generally requires removing pump from
1. Mark plug, lock nut, and housing to maintain original machine.
adjustment before removing screw adjustable relief
valve plug. Loosen lock nut (1-1/16" Hex) and remove
plug (8 mm Int. Hex). Remove O-ring from plug.
2. Remove spring and poppet from housing.
3. Inspect poppet and mating seat in housing for dam-
age or foreign material.
4. Install new O-ring on valve plug. Reinstall poppet and
spring. Reinstall plug and lock nut. Torque to 34 - 42
ft-lb (47-57 Nm), aligning marks made at disassembly.
5. Check and adjust, if necessary, charge pressure.
For screw adjustable “anti-stall” charge relief valves,
an approximate rule of thumb is 2.8 bar/quarter turn
(40 psi/quarter turn).
6. Measure charge pressure (port M3) with pump in
stroke. Charge pressure should level off when relief
setting is reached.
1. O-Ring 4. Sealant may be used on outside diameter
2. Seal 5. Inside Lip (face down)
3. Seal Carrier 6. Press Seal to Bottom of Seal Carrier
Figure 5-38. Installation of Shaft Seal
5-36 – JLG Lift – 3121180

1. Position pump with shaft facing up.
NOTE: If the unit is positioned horizontally when the shaft is

removed, the cylinder block could move out of
place, making shaft installation difficult.
2. Remove retaining ring from housing.

3. Pull out seal carrier assembly.
4. Remove O-ring from seal carrier. To install a new
shaft only, go to step 8.
5. Place seal carrier in an arbor press with shaft bear-
ing side down and press out old seal. An appropri-
ately sized pipe spacer or socket wrench can be
used as a press tool. Seal is not reusable.
6. Inspect seal carrier and new seal for damage.
Inspect sealing area on shaft for rust, wear, or con-
tamination. Polish sealing area on shaft if necessary.
7. Press new seal into shaft bearing side of seal carrier.
Seal lip must face outside of pump. Be careful not to
damage seal. Outside diameter of seal may be
coated with a sealant (e.g. Loctite High Performance
Sealant #59231) before installation. This aids in pre-
venting leaks caused by damage to seal bore in seal
carrier. If shaft is not being replaced go to step 11.
8. Remove shaft and roller bearing assembly from
pump or motor. Bearing assembly can be trans-
ferred to the new shaft (steps 9 and 10).
9. Remove retaining ring that secures roller bearing
assembly with a snap ring pliers. Remove roller
bearing assembly.
1. Key 4. Roller Bearing

2. Shaft Assembly 5. Shaft
3. Retaining Ring
Figure 5-39. Shaft Components
1. Place roller bearing assembly on new shaft and

secure with retaining ring.
2. Wrap spline or key end of shaft with thin plastic to
prevent damage to seal lip during installation. Lubri-
cate inside diameter of shaft seal with petroleum
jelly.
3. Place O-ring onto shaft bearing and lubricate with
petroleum jelly.
4. Slide seal carrier assembly over shaft and into housing
bore. Press against O-ring. Hold inward pressure
against shaft to compress cylinder block spring while
pressing seal carrier into place.
5. Install retaining ring.
3121180 – JLG Lift – 5-37

Charge Pump 7. Lubricate gerotor assembly with clean hydraulic oil

before assembly.
Disassemble charge pump to inspect and clean, or
8. Install gerotor drive pin into hole in drive coupling.
change auxiliary shaft drive coupling.
Apply grease or petroleum jelly to keep in place.
1. Remove auxiliary pump, if necessary.
9. Install drive coupling onto pump shaft with smaller
2. Remove screws retaining charge pump cover to outside diameter facing away from pump shaft. Dif-
pump housing (Torx T). Seven screws are used with ferent couplings are used with different auxiliary pad
“no pad” or SAE “A” auxiliary mounting pad charge options.
pump cover, and six screws are used with SAE “B”
10. Install gerotor assembly onto coupling.
auxiliary mounting pad charge pump cover. Remove
charge pump cover, gasket, and cover locating pins. 11. Install gerotor cover locating pin into pump housing.
Install gerotor cover assembly over gerotor. Locating
3. Remove gerotor cover assembly from charge pump
pin must engage slot in gerotor cover.
cover or back of pump housing. Remove gerotor
cover O-rings. Two O-rings are used on gerotor NOTE: Charge pump rotation is determined by location of
cover of all pumps. (An additional O-ring was used gerotor recess and pressure balance hole in gerotor
on gerotor cover of very early production pumps cover. Different gerotor covers are used for clock-
with SAE “A” pad option.) wise and counterclockwise rotation pumps.
4. Remove gerotor assembly from gerotor cover or
12. Install new pressure balance O-rings onto gerotor
pump housing.
cover and retain with petroleum jelly or grease. (An
5. Remove gerotor drive pin and drive coupling. Remove additional O-ring was used on gerotor cover of very
gerotor cover locating pin from pump housing. early production pumps with SAE ”A” pad option.)
6. Inspect each part separately if they are to be reused. 13. Install charge pump cover locating pins and new
If either gerotor assembly parts needs to be replaced, charge pump cover gasket.
they must both be replaced. Always replace O-rings
14. Install charge pump cover. Cover must engage gero-
and charge pump cover gasket. Inspect journal bear-
tor cover and locating pins. Install charge pump cover
ing in gerotor cover for excessive wear.
screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm).
15. Reinstall auxiliary pump if necessary.
5-38 – JLG Lift – 3121180

1. Cover Retaining Screw

2. O-Ring
3. Geroter Cover
4. Geroter Assembly
5. Drive Coupling
6. Geroter Cover Locating Pin
7. Charge Pump Cover Locating Pin
8. Geroter Drive Pin
9. Gasket
Figure 5-40. Charge Pump Components
3121180 – JLG Lift – 5-39

5.4 HYDRAULIC COMPONENT START-UP Inlet line from reservoir to pump must be filled prior to
start-up. Check inlet line for properly tightened fittings,
PROCEDURES AND restrictions, and air leaks.
RECOMMENDATIONS NOTE: In most cases, reservoir is above pump inlet so pres-
From a hydrostatic component standpoint, the goal at sure head created by higher oil level helps keep inlet
system start up is to put into functional operation, the pressures within an acceptable range and prevent
hydrostatic system in such a way as to preserve the high vacuum levels. However, due to hose routing or
designed life span of the system. Use the following start- low reservoir locations, air may be trapped within
up procedure whenever a new pump or motor is installed this line and must be bled. Bleed air by loosening
in a machine, or a system is restarted after a pump or hose at fitting closest to pump. When oil begins to
motor has been removed and reinstalled. flow, line is full, air has been purged, and the fitting
can be retightened to specified torque. If tank needs
to be pressurized to start low of oil, take a vacuum
reading at pump inlet during operation to verify
THE FOLLOWING PROCEDURE MAY REQUIRE MACHINE TO BE pump is not being asked to draw an inlet vacuum
DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNC- higher than its capability.
TIONS DISCONNECTED, ETC.) WHILE PERFORMING THE PROCE-
D U R E T O P R E V E N T I N J U R Y. TA K E N E C E S S A R Y S A F E T Y Fill pump and motor housing with clean hydraulic fluid
PRECAUTIONS BEFORE MOVING THE VEHICLE/MACHINE. prior to start up. Fill housing by pouring filtered oil in
upper case drain port.
Before installing pump and/or motor, inspect unit(s) for
damage that may have been incurred during shipping and NOTE: It is highly recommended to use the highest possible
handling. Make sure all system components (reservoir, case drain port. This ensures housing contains as
hoses, valves, fittings, heat exchanger, etc.) are clean much oil as possible and offers the greatest amount
before filling with fluid. of lubrication to internal components.
Fill reservoir with recommended hydraulic fluid. This fluid NOTE: In initial start-up conditions, it may be convenient to
should be passed through a 10 micron (nominal, no fill the housing before installing the case drain line.
bypass) filter before entering reservoir. Using contami- Component (especially motor) location may prevent
nated fluid can damage components, which may result in case drain port access after installation.
unexpected vehicle/machine movement.
NOTE: Make certain oil used to fill the component housing
is as clean as possible and store the fill container
IF A PUMP OR MOTOR IS REPLACED DUE TO INTERNAL DAM- properly to prevent it from becoming contaminated.
AGE, REMAINING UNITS (PUMP OR MOTORS) NEED TO BE
INSPECTED FOR DAMAGE AND CONTAMINATION, AND THE
ENTIRE HYDRAULIC SYSTEM FLUSHED AND FLUID REPLACED.
FAILURE TO DO SO MAY CAUSE CONSIDERABLE DAMAGE TO
THE ENTIRE SYSTEM.
5-40 – JLG Lift – 3121180

Install a 1000 psi (60 bar) pressure gauge in charge pres- Once charge pressure is established, increase speed to
sure gauge port to monitor charge pressure during start-up. normal operating RPM. Charge pressure should be as
indicated in the pump model code. If charge pressure is
It is recommended the external control input signal, (elec-
inadequate, shut down and determine cause of improper
trical connections for EDC), be disconnected at pump
pressure.
control until after initial start-up. This ensures pump
remains in its neutral position.
INADEQUATE CHARGE PRESSURE WILL AFFECT OPERATOR'S

ABILITY TO CONTROL THE MACHINE.
DO NOT START ENGINE UNLESS PUMP IS IN THE NEUTRAL
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
Shut down engine and connect the external control input
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
signal. Also reconnect the machine function(s), if discon-
ACTUATED DURING INITIAL START-UP.
nected earlier. Start engine, checking the pump remains in
neutral. With engine at normal operating RPM, slowly
”Jog” or slowly rotate engine until charge pressure starts
check forward and reverse machine operation.
to rise. Start engine and run at lowest possible RPM until
charge pressure is established. Excess air should be bled Charge pressure may slightly decrease during forward or
from system lines as close to motors as possible. reverse operation. Continue to cycle slowly between for-
ward and reverse for at least five minutes.
NOTE: With engine on low idle, ”crack”, (loosen-don't
remove), system lines at motor(s). Continue to run Shut down engine, remove gauges, and plug ports.
engine at low idle and tighten system lines as soon Check reservoir level and add filtered fluid if needed.
as oil is observed to leak from them. When oil is
Machine is now ready for operation.
observed to ”leak” at motor, line is full, air has been
purged, and system hoses should be retightened to
their specified torque.
3121180 – JLG Lift – 5-41

5.5 PRESSURE SETTING PROCEDURE Articulating Jib

Cold temperatures have a significant impact on pressure 1. Install a high pressure gauge on port marked “M3”
readings. JLG Industries Inc. recommends operating on Jib block, located on platform valve block.
machine until hydraulic system has warmed to normal
2. Activate Jib up or down. You should read 1500 psi
operating temperatures prior to checking pressures. JLG
(103 Bar).
Industries Inc. also recommends the use of a calibrated
gauge. Pressure readings are acceptable if they are within 3. The relief valve is located on the Jib block. Turn clock-
± 5% of specified pressures. wise to increase, counterclockwise to decrease.
Bang-Bang Main Relief Proportional Main Relief

1. Install a high pressure gauge at port marked “M1” 1. Install a high pressure gauge at port marked “M2”,
located on front face of valve block. located on front face of block.
2. Activate telescope in. 2. Raise boom up to end of stroke, or remove hose

from port #10 and plug and cap, then activate lift up.
3. Adjust relief valve to 3300 psi (227.5 Bar), located on
front face of block, it’s the 5th relief valve counting 3. This valve should be adjusted to 3200 psi (220 Bar).
left to right. Turn clockwise to increase and counter- This relief valve is located on front face of block and is
clockwise to decrease. the 4th relief valve counting left to right. Turn clock-
wise to increase, counterclockwise to decrease.
Steer
Lift Down
1. Install a high pressure gauge at port marked “M3”.
1. Install a high pressure gauge at port marked “M2”.
2. Activate steer and adjust relief valve to 2500 psi (172
Bar). The relief valve is located on front face of block, 2. Activate lift down.
3rd relief valve counting left to right. Turn clockwise to 3. This relief valve should be adjusted to 1200 psi. The
increase and counterclockwise to decrease. relief valve is located on front face of block, and is
the 2nd relief valve counting left to right. Turn clock-
Platform Level Up wise to increase, counterclockwise to decrease.
1. Install a high pressure gauge at the port marked
“M2”, located on the platform valve block. Swing
2. Activate level up to end of stroke. You should read 1. Left and right are done with (1) adjustment.
2800 psi (193 Bar). 2. Install a high pressure gauge at the port marked
3. The level up relief valve is located next to the check “M4”, located on the front face of the main valve.
port. Turn clockwise to increase and counterclock- 3. Either remove (1) of the swing hoses, plug and cap
wise to decrease. or swing turntable around until it hits the stop.
Platform Level Down 4. Activate swing. Pressure should be 1700 psi. The
relief valve is located on front face of block, the first
1. Install a high pressure gauge at port marked “M1”, relief valve counting left to right. Turn clockwise to
located on platform valve block. increase, counterclockwise to decrease
2. Activate level down to end of stroke, reading 1800
psi (125 Bar).
3. The level down relief valve is located next to the
check port. Turn clockwise to increase and counter-
clockwise to decrease.
5-42 – JLG Lift – 3121180

1. Check Valve 7. Upper Lift 13. Bang Bang Relief

2. Load Shuttle 8. Proportional Dump 14. Proportional Main
3. Load Shuttle 9. Directional Pilot Relief
4. Main Dump 10. Telescope 15. Steer Relief
5. Swing 11. Lower Lift 16. Load Shuttle (Steer)
6. Steer 12. Flow Regulator 17. Lift Down Relief
18. Swing Relief
Figure 5-41. Main Control Valve
3121180 – JLG Lift – 5-43

A 18-20 ft. lbs. (24.5 - 27.2 Nm)

B 4-5 ft. lbs. (5.4 - 6.8 Nm)
C 25-27 ft. lbs. (34 - 36.7 Nm)
Figure 5-42. Main Control Valve Torque Values
5-44 – JLG Lift – 3121180

1. Jib Up 8. Level Up Relief

2. Jib Down 9. Level Down Relief
3. Jib Up/Down Relief 10. Level Up Pilot Check
4. Rotate - Left 11. Level Down Pilot Check
5. Rotate - Right 12. Pressure Compensated
6. Level Up Regulator
7. Level Down
NOTE: Torque valves and cartridges 18 to 20 ft-lb (24.5 to 27.2 Nm).

Torque solenoid coils 4 to 5 ft-lb (6.5 to 9.5 Nm).
Figure 5-43. Platform Control Valve
3121180 – JLG Lift – 5-45

NOTES:
5-46 – JLG Lift – 3121180

SECTION 6. JLG CONTROL SYSTEM

6.1 INTRODUCTION Upper lift, swing, and drive are controlled by individual
joysticks. Steering is controlled by a rocker switch built
into the top of the drive joystick. To activate Drive, Lift, and
Swing pull up the slide lock on the joystick and move the
WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE handle in desired direction.
MACHINE, THE CONTROLLER MUST BE PROGRAMMED FOR The control system will control voltage output to valves
PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS AND and pump, as programmed for smooth operation and
PROPERLY CALIBRATING THE TILT SENSOR. maximum cycle time. Ground control speeds for all boom
functions can be programmed into the control system.
The JLG Control System controller has a built in LED to
AVOID PRESSURE-WASHING ELECTRICAL AND ELECTRONIC indicate any faults. The system stores recent faults which
COMPONENTS. IF PRESSURE-WASHING AREAS CONTAINING may be accessed for troubleshooting. Optional equip-
ELECTRICAL OR ELECTRONIC COMPONENTS, JLG INDUSTRIES, ment includes a soft touch system, head and tail lights,
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 and ground alarm. These options must be programmed
BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY into the control system when installed.
FROM THESE COMPONENTS. IF ELECTRICAL OR ELECTRONIC
The Control System may be accessed utilizing a custom
COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT
designed, hand held analyzer (Analyzer Kit, JLG part no.
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
2901443). It displays two lines of information at a time by
scrolling through the program.
The JLG designed Control System is a 12 volt based
motor control unit installed on the boom lift. NOTE: Each module has a label with the JLG part number
The JLG Control System has reduced the need for and a serial number which contains a date code.
exposed terminal strips, diodes, and trimpots. It provides
simplicity in viewing and adjusting various personality set- The following instructions are for the hand held analyzer.
tings for smooth control of acceleration, deceleration,
creep, and min and max.-speed for all boom, drive, and
steering functions.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
Return home or access
Level, and item menus
previous menu
Left & Right Arrow Keys

Up & Down Arrow Keys Used to move between Top Level,
Value Selector
Sub Level, and item menus
Figure 6-1. Hand Held Analyzer
3121180 – JLG Lift – 6-1

Figure 6-2. Control Module Location
6-2 – JLG Lift – 3121180

6.2 CONNECT JLG CONTROL SYSTEM MACHINE SETUP

CALIBRATIONS (view only)
ANALYZER
If you press ENTER, at the HELP: PRESS ENTER display,
1. Connect four pin end of cable supplied with analyzer and a fault is present, the analyzer display will scroll the
to controller module located on platform box or at fault across the screen. If no fault is detected, the display
controller module inside ground control box. Con- shows: HELP: EVERYTHING OK. If powered up at the
nect remaining end of cable to analyzer. ground station, the display shows: GROUND OK.
NOTE: Cable has a keyed four pin connector at each end. It If ENTER is pressed again, display shows the following:
cannot be connected backwards.
2. Power up Control System by turning lower key to

platform or ground position and pulling both emer-
gency stop buttons out.
6.3 USING ANALYZER

Analyzer displays the following with machine power on
and analyzer connected properly:
LOGGED HELP
1: POWER CYCLE (0/0)
Analyzer displays last system fault if any are present. Use
right and left arrow keys to scroll through fault logs and
view last 25 faults. Press ESC two times to return to MENU
screen. POWER CYCLE (0/0) indicates a power up.
HELP:
PRESS ENTER
Move between top level menu items using RIGHT and
LEFT arrow keys. To select a displayed menu item, press
ENTER. To cancel a selected menu item press ESC.
Scroll using right and left arrow keys to select a different
menu item.
Top level menus:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
3121180 – JLG Lift – 6-3

PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-3. Analyzer Connecting Points
6-4 – JLG Lift – 3121180

When a top level menu is selected, a new set of menu Use RIGHT arrow key to position cursor right one space
items may be offered: for example: to enter second digit of password.
DRIVE Use UP or DOWN arrow key to enter second digit of pass-
BOOM word which is 33271.
SYSTEM
Continue using arrow keys until all remaining digits of
DATALOG
password is shown.
VERSIONS
Once correct password is displayed, press ENTER.
Pressing ENTER with any above displayed menus show
Access level displays the following if password was
sub-menus within the selected menu. In some cases,
entered correctly:
such as DRIVE, the next level is parameter or information
to be changed. Refer to flow chart for what menus are
available within top level menus. You may only view per-
sonality settings for selected menus while in access level
2. Remember, you may always cancel a selected menu
item by pressing the ESC. key.
6.4 CHANGING HAND HELD ANALYZER

ACCESS LEVEL
When analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures a setting cannot be
accidentally changed. Enter password to change access
level. To enter password, scroll to ACCESS LEVEL menu.
For example:
MENU:
ACCESS LEVEL 1
Repeat above steps if correct access level is not displayed
or you can not adjust personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select ACCESS LEVEL menu.
Using UP or DOWN arrow keys, enter first digit of pass-
word, 3.
3121180 – JLG Lift – 6-5

Figure 6-4. ADE Control System Block Diagram
6-6 – JLG Lift – 3121180

6.5 ADJUSTING PARAMETERS USING THE 6.6 MACHINE SETUP

HAND HELD ANALYZER When a machine digit item is selected, press UP or DOWN
arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personality
item is selected, press UP or DOWN arrow keys to adjust
its value, for example:
GROUND ALARM:
2 = LIFT DOWN
PERSONALITIES: The effect of the machine digit value is displayed along
DRIVE ACCEL 1.0s with its value. Above display would be selected if machine
was equipped with a ground alarm and you wanted it to
There is a minimum and maximum value for efficient
sound when lifting down. There are certain settings
operation. Value will not increase if UP arrow is pressed at
allowed to install optional features or select the machine
maximum value and will not decrease if DOWN arrow is
model.
pressed at minimum value for any particular personality. If
value does not change when pressing up and down When selecting machine model to match machine size,
arrows, make sure you are at access level 1. personality settings default to factory recommended
setting.
NOTE: Refer to Table 6-1, Personality Ranges/Defaults, and

in this Service Manual for the recommended factory
settings.
NOTE: Password 33271 gives you access to level 1, which

permits you to change all machine personality set-
tings.
JLG strongly recommends you do not change the ELEVA-

TION CUTBACK setting.
CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY

AFFECT MACHINE PERFORMANCE.
3121180 – JLG Lift – 6-7

6-8
ACCESS LEVEL:
CODE 33271
MENU: ACCESS LEVEL: TO

ACCESS LEVEL 1 CODE 00000 PERSONALITIES:
TOWER LIFT
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PERSONALITIES DRIVE STEER LEFT TRACK RIGHT TRACK MAIN LIFT SWING
DRIVE: STEER: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

ACCEL X.XS MAX SPEED X% ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS

MIN FORWARD X% MIN FORWARD X% MIN FORWARD X% MIN UP X% MIN LEFT X%
MAX FORWARD X% MAX FORWARD X% MAX FORWARD X% MAX UP X% MAX LEFT X%
– JLG Lift –
MIN REVERSE X% MIN REVERSE X% MIN REVERSE X% CREEP UP X% CREEP LEFT X%
MAX REVERSE X% MAX REVERSE X% MAX REVERSE X% MIN DOWN X% MIN RIGHT X%

ELEV. MAX X% ELEV F MAX X% ELEV F MAX X% MAX DOWN X% MAX RIGHT X%
CREEP MAX X% ELEV R MAX X% ELEV R MAX X% CREEP DOWN X% CREEP RIGHT X%
LEFT TRACK: RIGHT TRACK:

CREEP F MAX X% CREEP F MAX X%

CREEP R MAX X% CREEP R MAX X%
TO Note: Some screens may not be available depending upon machine configuration.
MENU:
MACHINE SETUP
Figure 6-1. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
3121180
3121180
FROM
PERSONALITIES:
SWING
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

TOWER LIFT UPPER TELESCOPE TOWER TELESCOPE BASKET LEVEL BASKET ROTATE JIB LIFT GROUND MODE GEN SET/WELDER
TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE: GEN SET/WELDER:
ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS U. LIFT UP X% ENGINE 1800 RPM
TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS U. LIFT DOWN X%
MIN UP X% MIN IN X% MIN IN X% MIN UP X% MIN LEFT X% MIN UP X% SWING X%
MAX UP X% MAX IN X% MAX IN X% MAX UP X% MAX LEFT X% MAX UP X% BASKET LEVEL X%
– JLG Lift –
MIN DOWN X% MIN OUT X% MIN OUT X% MIN DOWN X% MIN RIGHT X% MIN DOWN X% BASKET ROTATE X%
MAX DOWN X% MAX OUT X% MAX OUT X% MAX DOWN X% MAX RIGHT X% MAX DOWN X% UPPER TELE X%
GROUND MODE:
TOWER TELE X%
GROUND MODE:
T. LIFT UP X%
GROUND MODE:
T. LIFT DN X%
GROUND MODE:
JIB (U/D) X%
6-9
6-10
FROM
MENU:
PERSONALITIES
MENU: MODEL NUMBER: ENGINE: GLOW PLUG: ENGINE SHUTDOWN: TILT: TOWER LIFT: TOWER TELE: JIB: 4 WHEEL STEER:
MACHINE SETUP 1=400 1=FORD EFI GAS 0=NO GLOW PLUGS 1=SHUTDOWN 1=5 DEG 0=NO 0=NO 0=NO 0=NO
MODEL NUMBER: ENGINE: GLOW PLUG: ENGINE SHUTDOWN: TILT: TOWER LIFT: TOWER TELE: JIB: 4 WHEEL STEER:
2=450 2=FORD EFI D/F 15=15 SECONDS 0=NO 2=4 DEG 1=YES 1=YES 0=YES 0=YES
TO MODEL NUMBER: ENGINE: TILT:

MENU: 3=600 3=DEUTZ F4 3=3 DEG
CALIBRATIONS
MODEL NUMBER: ENGINE: TILT:
4=601 4=DEUTZ F3 4=4 DEG + CUT
MODEL NUMBER: ENGINE: TILT:

5=800A 5=CAT. 3024C 5=3 DEG + CUT
MODEL NUMBER: ENGINE:

6=800S 6=CAT. 3044C
MODEL NUMBER:
9=600C
MODEL NUMBER:
10=510A
– JLG Lift –
MODEL NUMBER:
11=740A
SOFT TOUCH: GEN SET/WELDER: H & T LIGHTS: CABLE SWITCH: LOAD: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: T PROX SWITCHES: DRIVE: FLYWHEEL TEETH:
0=NO 0=NO 0=NO 0=NO 0=NO 0=1 ON ROTATOR 0=NO 0=NO 0=NO 0=4WD 0=133 TEETH
SOFT TOUCH: GEN SET/WELDER: H & T LIGHTS: CABLE SWITCH: LOAD: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: T PROX SWITCHES: DRIVE: FLYWHEEL TEETH:
1=YES 1=BELT DRIVE 1=YES 1=YES 1=WARN ONLY 1=4 UNDER BASKET 1=BOOM CUTOUT 1=DRIVE 1=YES 1=2WD 1=110 TEETH
GEN SET/WELDER: LOAD: FUNCTION CUTOUT: GROUND ALARM:

2=HYD. DRIVE 2=CUTOUT PLAT 2=DRIVE CUTOUT 2=LIFT DOWN
LOAD: FUNCTION CUTOUT: GROUND ALARM:

3=CUTOUT ALL 3=DRIVE CUT E&T 3=BOOM & DRIVE
LOAD:
4=SPECIAL 1
3121180
3121180
– JLG Lift –
6-11
6-12
– JLG Lift –
NOTE: Some screens may not be available depending upon machine configuration.
Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
3121180
3121180
– JLG Lift –
6-13
6-14
FROM:
MENU:
PERSONALITIES
MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: SOFT TOUCH:
MACHINE SETUP 400S ANSI USA FORD EFI GAS 110 TEETH NO GLOW PLUGS DISABLED ENABLED 5 DEGREES NO NO NO
MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: SOFT TOUCH:
450A ANSI EXPORT FORD EFI D/F 133 TEETH AIR INTAKE ENABLED DISABLED 4 DEGREES YES YES YES
MODEL NUMBER: MARKET: ENGINE: GLOW PLUG: TILT:
510A CSA DEUTZ F4 TIER1 IN-CYLINDER 3 DEGREES
TO: MODEL NUMBER: MARKET: ENGINE: TILT:

MENU: 600S CE DEUTZ F3 TIER1 4 DEGREES + CUT
CALIBRATIONS
MODEL NUMBER: MARKET: ENGINE: TILT:
600A AUSTRALIA CAT. 3024C 3 DEGREES + CUT
MODEL NUMBER: MARKET: ENGINE:
600SC JAPAN CAT. 3044C
601S PERKINS 404C
740A DEUTZ F4 TIER2
800A DEUTZ F3 TIER2
800S FORD GAS TIER2
– JLG Lift –
ENGINE:
FORD D/F TIER2
ENGINE:
DEUTZ ECM
ENGINE:
DUAL FUEL ECM
GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: CABLE SWITCH: LOAD SYSTEM: LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: LEVELING MODE:
NO MOTION ENABLED NO NO NO 4 UNDER PLATFORM NO NO 4WD CELSIUS ALL FUNCTIONS
GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: CABLE SWITCH: LOAD SYSTEM: LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: LEVELING MODE:
BELT DRIVE MOTION CUTOUT YES YES WARN ONLY 1 ON ROTATOR BOOM CUTOUT DRIVE 2WD FAHRENHEIT LIFT/TELESCOPE
LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM: DRIVE:
CUTOUT PLATFORM DRIVE CUTOUT DESCENT 2WD W/ 2-SPEED
LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:
CUTOUT ALL DRIVE CUT E&T MOTION
LOAD SYSTEM:
SPECIAL 1
3121180
FROM:
MENU:
MACHINE SETUP
3121180
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:
CALIBRATIONS TILT SENSOR UMS SENSOR DEUTZ SETUP LEVEL UP CRKPT LEVEL DOWN CRKPT
TILT SENSOR UMS SENSOR: DEUTZ SETUP LEVEL UP CRKPT LEVEL DOWN CRKPT
CALIBRATE? CALIBRATE? SETUP X CALIBRATE? CALIBRATE?
MENU: HELP:
HELP:PRESS ENTER GROUND MODE OK
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS DRIVE/STEER BOOM FUNCTIONS ENGINE SYSTEM UMS LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE CHASSIS TILT PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV ANGLE XXX.X STATE:OK RX/SEC: X LOAD ZERO: XXX ON: XXH XXM SOFTWARE: P5.X
JOYSTICK STEER: JOYSTICK SWING: AIR FILTER PLATFORM MODULE UMS TO TURNTABLE PERCENT OF MAX CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% SWITCH: OPEN BATTERY: XX.XV ANGLE XXX.X LOAD: XXXX% TX/SEC: X LOAD 500LB: XXX ENGINE: XH XM CNST. DATA: PX.X
DRIVE OUTPUT: LIFT OUTPUT: BATTERY VOLTAGE: AMBIENT UMS INCLINATION CAPACITY ANGLE CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% XX.XV TEMPERATURE:XXXC ANGLE XXX.X SWITCH: CLOSED BUS OFF: X PLATFORM UP: XXX DRIVE: XH XM HARDWARE: REV X
STEER OUTPUT: SWING OUTPUT: COOLANT PLATFORM SELECT UMS STATUS: CAPACITY LENGTH CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% TEMPERATURE:XXXC KEYSWITCH: OPEN NORMAL SWITCH: CLOSED PASSIVE: 1 PLATFORM DN: XXX LIFT: XH XM S/N: XXXXXX
LEFT TRACK PLATFORM LEVEL: ELECTRIC FAN GROUND SELECT CAN STATISTICS DATALOG: PLATFORM MODULE
OUTPUT: FWD XXX% UP XXX% OUTPUT: OFF KEYSWITCH:CLOSED MSG ERROR: XXXX SWING: XH XM SOFTWARE: P5.0
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RIGHT TRACK PLATFORM ROTATE: ELECTRIC FUEL STATION CONTROL: DATALOG: PLATFORM MODULE
OUTPUT: FWD XXX% RIGHT XXX% PUMP OUTPUT: OFF GROUND TELE: XH XM HARDWARE: REV X
STEER TYPE: MAIN TELESCOPE: ENGINE OIL FOOTSWITCH INPUT CREEP GENSET/WELDER DATALOG: PLATFORM MODULE
– JLG Lift –
NORMAL IN XXX% PRESSURE:XXXXPSI GROUND: OPEN SWITCH: CLOSED SWITCH: OPEN MAX TEMP: XXC S/N: XXXXXX
BRAKES STATUS: TOWER TELESCOPE: FUEL SELECTION FOOTSWITCH INPUT CREEP MODE: LIGHTS DATALOG: PROPULSION MOD.
LOCKED IN XXX% SWITCH:GAS PLATFORM: CLOSED OFF SWITCH: OPEN MIN TEMP: XXC SOFTWARE: PX.X
CREEP TOWER LIFT: FUEL SELECTION TRANSPORT CHASSIS TILT: PLATFORM TILT1 DATALOG: ANALYZER:
SWITCH: CLOSED DOWN XXX% STATUS:GAS SWITCHES: OPEN XX.X DEGREES ANGLE: XX.X DEG MAX VOLTS: XX.XV ANALYZER V6.3
CREEP MODE: JIB LIFT: AMBIENT TRANSPORT MODE: AUXILIARY POWER PLATFORM TILT2 DATALOG:
OFF UP XXX% TEMPERATURE:XXXC OUT OF TRANSPORT SWITCH: OPEN ANGLE: XX.X DEG RENTAL: XH XM
2-SPEED PLATFORM CONTROL FUEL LEVEL END OF STROKE HORN PLATFORM TILT1 DATALOG:
SWITCH: OPEN VALVE: OFF SENSOR: OK PROXIMITY: OPEN SWITCH: OPEN VOLTAGE: XXXX MV ERASE RENTAL?
2-SPEED VALVE FUNCTION SPEED: STARTER TOWER LIFT RETURN HYDRAULIC PLATFORM TILT2
OUTPUT: OFF PUMP POT XXX% CRANK TIME: XX S PROXIMITY:CLOSED FILTER: OPEN VOLTAGE: XXXX MV
HIGH ENGINE CREEP ENGINE SPEED TOWER TELESCOPE CHARGE PUMP CHASSIS TILT:
SWITCH: OPEN SWITCH: CLOSED ACTUAL: XXXX RPM PROXIMITY:CLOSED FILTER: OPEN X-AXIS XX.X
DRIVE MODE: CREEP MODE: ENGINE SPEED TOWER POSITION: SOFT TOUCH LIMIT CHASSIS TILT:
MID ENGINE OFF TARGET: XXXX RPM UP/RETRACTED SWITCH: OPEN Y-AXIS XX.X
CABLE BREAK SOFT TOUCH

SWITCH: CLOSED OVERRIDE: OPEN
MENU: SYSTEM TEST:

SYSTEM TEST ACTIVATE?
6-15
GO TO PAGE 6-18
GO TO PAGE 6-17
PERSONALITIES:
PLATFORM LEVEL
4 WHEEL STEER:
DIAGNOSTICS:
O
F
VERSIONS
DRIVE:
4WD
NO
GO TO PAGE 6-17
GO TO PAGE 6-18
GO TO PAGE 6-18
1
TOWER TELESCOPE
PERSONALITIES:
GROUND ALARM:
CALIBRATIONS:
DIAGNOSTICS:
PROP MODULE
N
S
E
DATALOG
MOTION
JIB:
NO
LEVEL DOWN CRKPT:

GO TO PAGE 6-18
1
1
1
CALIBRATIONS: 1
1
1
CALIBRATION DATA
CALIBRATION DATA
CALIBRATION DATA
CALIBRATION DATA
CALIBRATION DATA
FUNCTION CUTOUT:
LEVEL DOWN CRKPT

PERSONALITIES:
MAIN TELESCOPE
DIAGNOSTICS:
PLATFORM UP:
PLATFORM DN:
LOAD 500LB:
LOAD ZERO:
CALIBRATE?
M
5 DEGREES
TILT:
NO

GO TO PAGE 6-18
LEVEL UP CRKPT: 1
CALIBRATIONS: 1
ENGINE SHUTDOWN:
4 UNDER PLATFORM
CAN STATISTICS
CAN STATISTICS
CAN STATISTICS
CAN STATISTICS
CAN STATISTICS
PERSONALITIES:
LEVEL UP CRKPT
CAN STATISTICS
MSG ERROR: X
LOAD SENSOR:
DIAGNOSTICS:
BUS OFF: X
PASSIVE: X
TOWER LIFT
CALIBRATE?
RX/SEC: X
TX/SEC: X
ENABLED
GO TO PAGE 6-18
PLAT. LEVELING: 1
CALIBRATIONS: 1
STARTER LOCKOUT:
CAPACITY LENGTH
FUEL TANK SIZE:

SWITCH: CLOSED
CAPACITY ANGLE
SWITCH: CLOSED
PERCENT OF MAX
PERSONALITIES:
PLAT. LEVELING
PLATFORM LOAD
DIAGNOSTICS:
LOAD SYSTEM:
LOAD: XXX%
CALIBRATE?
K
STATE: OK
31 GALLON
DISABLED
SWING
LOAD
NO
GO TO PAGE 6-18
1
UMS TO TURNTABLE
CRIBBING OPTION:
UMS INCLINATION
PERSONALITIES:
A DIAGNOSTICS:
DRIVE/STEER B
DIAGNOSTICS:
BOOM FUNCTIONS C
DIAGNOSTICS:
ENGINE D
DIAGNOSTICS:
SYSTEM
E
DIAGNOSTICS:
DATALOG F
DIAGNOSTICS:
VERSIONS
JOYSTICK DRIVE:
FORWARD XXX%
JOYSTICK LIFT:
MAIN UP XXX%
START SEQUENCE:
NOT ACTIVE
GROUND MODULE:
BATTERY: XX:XV
DATALOG:
ON: XXXh XXm
GROUND MODULE
SOFTWARE: XX.XX
JOYSTICK STEER:
LEFT XXX%
JOYSTICK SWING:
LEFT XXX%
BATTERY VOLTAGE:
XX.XV
PLATFORM MODULE:
BATTERY: XX:XV
DATALOG:
ENGINE: XXXh XXm
GROUND MODULE
COST. DATA:XX.XX
DRIVE OUTPUT:
FORWARD XXX%
LIFT OUTPUT:
MAIN UP XXX%
COOLANT
TEMPERATURE:XXXF
AMBIENT
TEMPERATURE:XXXF
DATALOG:
DRIVE: XXXh XXm
GROUND MODULE
HARDWARE: REV XX
COMMANDED:XXXXMA
DRIVE FORWARD
LEFT XXX%
SWING OUTPUT:
OUTPUT: OFF
ELECTRIC FAN
KEYSWITCH: OPEN
PLATFORM SELECT
LIFT: XXXh XXm
DATALOG:
S/N: XXXXXX
GROUND MODULE
DRIVE REVERSE
COMMANDED:XXXXMA
PLATFORM LEVEL:
UP XXX%
ELECTRIC FUEL
PUMP OUTPUT: OFF
GROUND SELECT
KEYSWITCH: OPEN
DATALOG:
SWING: XXXh XXm
PLATFORM MODULE
SOFTWARE: XX.XX
DRIVE OUTPUT:
ACTUAL: XXXXMA
PLATFORM ROTATE:
LEFT XXX%
ENGINE OIL
PRESSURE:XXX PSI
STATION CONTROL:
GROUND
DATALOG:
TELE: XXXh XXm
PLATFORM MODULE
HARDWARE: REV XX
STEER OUTPUT:
LEFT XXX%
MAIN TELESCOPE:
IN XXX%
FUEL SELECTION
SWITCH: GAS
FOOTSWITCH INPUT
GROUND: OPEN
DATALOG:
MAX TEMP: XXXF
PLATFORM MODULE
S/N: XXXXXX
LEFT TRACK
OUTPUT: FWD XXX%
TOWER TELESCOPE:
IN XXX%
AMBIENT
TEMPERATURE:XXXF
FOOTSWITCH INPUT
PLATFORM: OPEN
DATALOG:
MIN TEMP: XXXF
PROPULSION MOD
SOFTWARE: XX.XX
LEFT TRACK FWD

COMMANDED:XXXXMA
TOWER LIFT:
UP XXX% UP XXX%
TOWER LIFT:
SWITCHES: OPEN
TRANSPORT DATALOG:
MAX VOLTS: XX.XV
TCU MODULE
SOFTWARE: XX.XX
LEFT TRACK REV

COMMANDED:XXXXMA
JIB LIFT:
UP XXX%
FUEL LEVEL
SENSOR: OK
TRANSPORT MODE:
OUT OF TRANSPORT
DATALOG:
RENTAL: XXXh XXm
TCU MODULE
HARDWARE: XX.XX
LEFT TRACK
ACTUAL: XXXXMA
PLATFORM CONTROL
VALVE: OFF
STARTER
CRANK TIME: XX S
END OF STROKE
PROXIMITY:CLOSED
DATALOG:
ERASE RENTAL?
1 CLEAR RENTAL:
YES:ENTER,NO:ESC
1 TCU MODULE
S/N: XXXXXX
RIGHT TRACK
OUTPUT: FWD XXX%
FUNCTION SPEED:
PUMP POT XXX%
ENGINE SPEED
ACTUAL: XXXX RPM
TOWER LIFT
PROXIMITY:CLOSED
GATEWAY MODULE
SOFTWARE: XX.XX
RIGHT TRACK FWD

COMMANDED:XXXXMA
CREEP
SWITCH: CLOSED
ENGINE SPEED
TARGET: XXXX RPM
TOWER TELESCOPE
PROXIMITY:CLOSED
GATEWAY MODULE
HARDWARE: REV XX
RIGHT TRACK REV

COMMANDED:XXXXMA
CREEP MODE:
OFF
TOWER POSITION:
RETRACTED
ANALYZER
ANALYZER: XX.XX
RIGHT TRACK
ACTUAL:XXXXMA
CABLE BREAK
SWITCH: CLOSED
STEER TYPE:
NORMAL
CREEP
SWITCH: CLOSED
BRAKES STATUS:
LOCKED
CREEP MODE:
OFF
CREEP:
SWITCH: CLOSED
CHASSIS TILT:
XX.X DEGREES
CREEP MODE:
OFF
CHASSIS TILT
X-AXIS: XX.X
2-SPEED:
SWITCH: OPEN
CHASSIS TILT
Y-AXIS: XX.X
2-SPEED VALVE
OUTPUT: OFF
AUXILIARY POWER
SWITCH: OPEN
HIGH ENGINE
SWITCH: OPEN
HORN
SWITCH: OPEN
DRIVE MODE:
MID ENGINE
RETURN HYDRAULIC
FILTER: OPEN
FEATURE:DISABLED
DRV. ORIENTATION CHARGE PUMP
FILTER: OPEN
DRV. ORIENTATION
SWITCH: OPEN SWITCH: OPEN
SOFT TOUCH LIMIT
DRV. ORIENTATION
OVERRIDE: OPEN
SOFT TOUCH
OVERRIDE: OPEN
DRV. ORIENTATION
STATUS:CONFIRMED
GENSET.WELDER
SWITCH: OPEN
DRIVE CONTROL:
NORMAL
LIGHTS
SWITCH: OPEN
DISABLED
CRIBBING MODE: PLATFORM TILT1
ANGLE: XX.X
ANGLE: XX.X
PLATFORM TILT2
PLATFORM TILT1
VOLTAGE: XX MV
PLATFORM TILT2
VOLTAGE: XX MV
CABLE SWITCH:
CALIBRATIONS:
DIAGNOSTICS:
CHASSIS TILT
ANGLE: XX.X
ANGLE: XX.X
ANGLE: XX.X
IN-CYLINDER
DEUTZ SETUP
DEUTZ SETUP
UMS STATUS
GLOW PLUG:
MAIN LIFT
SETUP X
NORMAL
UMS
NO
NO
GO TO PAGE 6-17
GO TO PAGE 6-18
1
FLYWHEEL TEETH:
PERSONALITIES:
PERSONALITIES:
GEN SET/WELDER
PERSONALITIES:
GEN SET/WELDER
H & T LIGHTS:
CALIBRATIONS:
CALIBRATIONS:
DIAGNOSTICS:
RIGHT TRACK
LOAD SENSOR
TILT SENSOR
D
133 TEETH
CLEARSKY:
I
SYSTEM
NO
NO
GO TO PAGE 6-17
GO TO PAGE 6-18
GO TO PAGE 6-18
1
1
GEN SET CUTOUT:
DISABLE RS-485?
PERSONALITIES:
PERSONALITIES:
MOTION ENABLED
DRIVE CONTROL:
CALIBRATIONS:
DIAGNOSTICS:
FORD ENGINE:
GROUND MODE
PERKINS ECM
FORD ENGINE
LEFT TRACK
H
C
ENHANCED
ENGINE:
ENGINE
GO TO PAGE 6-18
GO TO PAGE 6-17
1
1
1
GEN SET/WELDER:
BOOM FUNCTIONS
PERSONALITIES:
MAX SPEED XXX%
PERSONALITIES:
LEVELING MODE:
ALL FUNCTIONS
CALIBRATIONS:
SERVICE MODE:
DIAGNOSTICS:
UMS SENSOR:
UMS SENSOR:
CALIBRATE?
UMS SENSOR
Q
B
RAW: XX.X
TEST UMS?
TEST UMS?
JIB LIFT
ANSI USA
MARKET:
STEER:
STEER
NO
NO
GO TO PAGE 6-18
GO TO PAGE 6-17
GO TO PAGE 6-18
SERVICE MODE: 1
1
1
TOWER LIFT DOWN?
(001)
EVERYTHING OKAY
PLATFORM ROTATE
PERSONALITIES:
PERSONALITIES:
ACCESS LEVEL:
MODEL NUMBER:
CALIBRATIONS:
SERVICE MODE:
x:xxxxxxxxxxx
DIAGNOSTICS:
TILT SENSOR:
SYSTEM TEST:
TEMPERATURE:
DRIVE/STEER
CODE XXXXXX
SOFT TOUCH:
TILT SENSOR
CALIBRATE?
CODE XXXXX
G
P
LOG:(xxx)
ACTIVATE?
FARENHEIT
HELP:
DRIVE
400S
NO
1
HELP:PRESS ENTER
PERSONALITIES
MACHINE SETUP
ACCESS LEVEL
CALIBRATIONS
SERVICE MODE
DIAGNOSTICS
SYSTEM TEST
MENU:
MENU:
MENU:
MENU:
MENU:
MENU:
MENU:
MENU:
6-16 – JLG Lift – 3121180

DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:

A DRIVE/STEER B BOOM FUNCTIONS C ENGINE D SYSTEM
E DATALOG F VERSIONS
JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE: DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX:XV ON: XXXh XXm SOFTWARE: XX.XX
JOYSTICK STEER: JOYSTICK SWING: BATTERY VOLTAGE: PLATFORM MODULE: DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% XX.XV BATTERY: XX:XV ENGINE: XXXh XXm COST. DATA:XX.XX
DRIVE OUTPUT: LIFT OUTPUT: COOLANT AMBIENT DATALOG: GROUND MODULE

FORWARD XXX% MAIN UP XXX% TEMPERATURE:XXXF TEMPERATURE:XXXF DRIVE: XXXh XXm HARDWARE: REV XX
DRIVE FORWARD SWING OUTPUT: ELECTRIC FAN PLATFORM SELECT DATALOG: GROUND MODULE
COMMANDED:XXXXMA LEFT XXX% OUTPUT: OFF KEYSWITCH: OPEN LIFT: XXXh XXm S/N: XXXXXX
DRIVE REVERSE PLATFORM LEVEL: ELECTRIC FUEL GROUND SELECT DATALOG: PLATFORM MODULE
COMMANDED:XXXXMA UP XXX% PUMP OUTPUT: OFF KEYSWITCH: OPEN SWING: XXXh XXm SOFTWARE: XX.XX
DRIVE OUTPUT: PLATFORM ROTATE: ENGINE OIL STATION CONTROL: DATALOG: PLATFORM MODULE
ACTUAL: XXXXMA LEFT XXX% PRESSURE:XXX PSI GROUND TELE: XXXh XXm HARDWARE: REV XX
STEER OUTPUT: MAIN TELESCOPE: FUEL SELECTION FOOTSWITCH INPUT DATALOG: PLATFORM MODULE
LEFT XXX% IN XXX% SWITCH: GAS GROUND: OPEN MAX TEMP: XXXF S/N: XXXXXX
LEFT TRACK TOWER TELESCOPE: AMBIENT FOOTSWITCH INPUT DATALOG: PROPULSION MOD
OUTPUT: FWD XXX% IN XXX% TEMPERATURE:XXXF PLATFORM: OPEN MIN TEMP: XXXF SOFTWARE: XX.XX
LEFT TRACK FWD TOWER LIFT: TOWER LIFT: TRANSPORT DATALOG: TCU MODULE
COMMANDED:XXXXMA UP XXX% UP XXX% SWITCHES: OPEN MAX VOLTS: XX.XV SOFTWARE: XX.XX
LEFT TRACK REV JIB LIFT: FUEL LEVEL TRANSPORT MODE: DATALOG: TCU MODULE
COMMANDED:XXXXMA UP XXX% SENSOR: OK OUT OF TRANSPORT RENTAL: XXXh XXm HARDWARE: XX.XX
LEFT TRACK PLATFORM CONTROL STARTER END OF STROKE DATALOG: 1 CLEAR RENTAL: 1 TCU MODULE
ACTUAL: XXXXMA VALVE: OFF CRANK TIME: XX S PROXIMITY:CLOSED ERASE RENTAL? YES:ENTER,NO:ESC S/N: XXXXXX
RIGHT TRACK FUNCTION SPEED: ENGINE SPEED TOWER LIFT GATEWAY MODULE
OUTPUT: FWD XXX% PUMP POT XXX% ACTUAL: XXXX RPM PROXIMITY:CLOSED SOFTWARE: XX.XX
RIGHT TRACK FWD CREEP ENGINE SPEED TOWER TELESCOPE GATEWAY MODULE
COMMANDED:XXXXMA SWITCH: CLOSED TARGET: XXXX RPM PROXIMITY:CLOSED HARDWARE: REV XX
RIGHT TRACK REV CREEP MODE: TOWER POSITION: ANALYZER

COMMANDED:XXXXMA OFF RETRACTED ANALYZER: XX.XX
RIGHT TRACK CABLE BREAK

ACTUAL:XXXXMA SWITCH: CLOSED
STEER TYPE: CREEP

NORMAL SWITCH: CLOSED
BRAKES STATUS: CREEP MODE:

LOCKED OFF
CREEP: CHASSIS TILT:

SWITCH: CLOSED XX.X DEGREES
CREEP MODE: CHASSIS TILT

OFF X-AXIS: XX.X
2-SPEED: CHASSIS TILT

SWITCH: OPEN Y-AXIS: XX.X
2-SPEED VALVE AUXILIARY POWER

OUTPUT: OFF SWITCH: OPEN
HIGH ENGINE HORN

DRIVE MODE: RETURN HYDRAULIC

MID ENGINE FILTER: OPEN
DRV. ORIENTATION CHARGE PUMP

FEATURE:DISABLED FILTER: OPEN
DRV. ORIENTATION SOFT TOUCH LIMIT

DRV. ORIENTATION SOFT TOUCH

OVERRIDE: OPEN OVERRIDE: OPEN
DRV. ORIENTATION GENSET.WELDER

STATUS:CONFIRMED SWITCH: OPEN
DRIVE CONTROL: LIGHTS

NORMAL SWITCH: OPEN
CRIBBING MODE: PLATFORM TILT1

DISABLED ANGLE: XX.X
PLATFORM TILT2
ANGLE: XX.X
PLATFORM TILT1
VOLTAGE: XX MV
PLATFORM TILT2
VOLTAGE: XX MV
3121180 – JLG Lift – 6-17

PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

G DRIVE H LEFT TRACK I RIGHT TRACK
J MAIN LIFT K SWING L TOWER LIFT M MAIN TELESCOPE
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE:
ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS
MIN FORWARD XXX% MIN FORWARD XXX% MIN FORWARD XXX% MIN UP XXX% MIN LEFT XXX% MIN UP XXX% MIN IN XXX%
MAX FORWARD XXX% MAX FORWARD XXX% MAX FORWARD XXX% MAX UP XXX% MIN RIGHT XXX% MAX UP XXX% MAX IN XXX%
MIN REVERSE XXX% MIN REVERSE XXX% MIN REVERSE XXX% CREEP UP XXX% CREEP LEFT XXX% MIN DOWN XXX% MIN OUT XXX%
MAX REVERSE XXX% MAX REVERSE XXX% MAX REVERSE XXX% MIN DOWN XXX% MIN RIGHT XXX% MAX DOWN XXX% MAX OUT XXX%

ELEV. MAX XXX% ELEV F MAX XXX% ELEV F MAX XXX% MAX DOWN XXX% MAX RIGHT XXX%

CREEP MAX XXX% ELEV R MAX XXX% ELEV R MAX XXX% CREEP DOWN XXX% CREEP RIGHT XXX%

CREEP F MAX XXX% CREEP F MAX XXX%

CREEP R MAX XXX% CREEP R MAX XXX%
TRACK COUNTER
ROTATE MAX XXX%
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: CALIBRATIONS:

N TOWER TELESCOPE O PLATFORM LEVEL P PLATFORM ROTATE
Q JIB LIFT R GROUND MODE S PROP MODULE
TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE: PROP MODULE 1
ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS MAIN UP: XXX% J1-7 MIN: XXX
TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE: PROP MODULE: 1
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS MAIN DOWN: XXX% J1-7 MAX: XXX
MIN IN XXX% MIN IN XXX% MIN LEFT XXX% MIN UP XXX% SWING XXX% J1-8 MIN: XXX
MAX IN XXX% MAX IN XXX% MAX LEFT XXX% MAX UP XXX% PLT LEVEL XXX% J1-8 MAX: XXX
MIN OUT XXX% MIN OUT XXX% MIN RIGHT XXX% MIN DOWN XXX% PLT ROTATE: XXX% J1-9 MIN: XXX
MAX OUT XXX% MAX OUT XXX% MAX RIGHT XXX% MAX DOWN XXX% MAIN TELE: XXX% J1-9 MAX: XXX
GROUND MODE: PROP MODULE: 1

TOWER TELE: XXX% J1-10 MIN: XXX

TOWER UP: XXX% J1-10 MAX XXX

TOWER DOWN: XXX% DEADBAND: XXXXX

JIB LIFT: XXX% FF NUM: XXXXX

JIB SWING: XXX% FF DEN: XXXXX
PROP MODULE: 1
I NUM: XXXXX
PROP MODULE: 1
I DEN: XXXXX
PROP MODULE: 1
NEG ERR: XXXXX
PROP MODULE: 1
GAIN FLAG: XXXXX
6-18 – JLG Lift – 3121180

6.7 MACHINE PERSONALITY SETTINGS NOTE: Adjust personality settings within range for optimum
machine performance.
Table 6-1. Personality Ranges/Defaults
FUNCTION PERSONALITY RANGE DEFAULTS
DRIVE ACCELeration 0.1s to 5.0s 1.5
DECELeration 0.1s to 3.0s 1.5
MINimum speed 0 to 35% 30
MAXimum speed 0 to 100% 50
REVerse MINimum speed 0 to 35% 30
REVerse MAXimum speed 0 to 100% 50
ELEVATED MAXimum speed 0 to 50% 38
CREEP MAXimum speed 0 to 50% 40
Engine RPM 800 to 2900 1800
TOWER LIFT ACCELeration 0.1 to 5.0 1.0
DECELeration 0.1 to 3.0 1.0
MlNimum UP speed 0 to 60% 28
MAXimum UP speed 0 to 100% 45
MINimum DOWN speed 0 to 60% 27
MAXimum DOWN speed 0 to 100% 42
UPPER LIFT ACCELeration 0.1 to 5.0 2.0
MlNimum UP speed 0 to 60% 36
CREEP Maximum UP speed 0 to 65% 40
CREEP maximum DOWN speed 0 to 75% 37
3121180 – JLG Lift – 6-19

SWING ACCELeration 0.1 to 5.0s 2.0
DECELeration 0.1 to 3.0s 1.5
MINimum LEFT speed 0 to 50% 32
MAXimum LEFT speed 0 to 100% 58
CREEP maximum LEFT speed 0 to 65% 40
MINimum RIGHT speed 0 to 50% 38
MAXimum RIGHT speed 0 to 100% 58
CREEP maximum RIGHT speed 0 to 65% 40
TELESCOPE UPPER ACCELeration 0.1 to 5.0 2.0
MINimum IN speed 0 to 65% 27
MAXimum IN speed 0 to 100% 40
MINimum OUT speed 0 to 65% 27
MAXimum OUT speed 0 to 100% 37
BASKET LEVEL ACCELeration 0.1 to 5.0 2.5
MINimum UP speed 0 to 65% 15
MlNimum DOWN speed 0 to 65% 17
BASKET ROTATE ACCELeration 0.1 to 5.0 2.0
MlNimum LEFT speed 0 to 65% 15
MAXimum LEFT speed 0 to 100% 25
MINimum RIGHT speed 0 to 65% 15
MAXimum RIGHT speed 0 to 100% 25
6-20 – JLG Lift – 3121180

JIB LIFT ACCELeration 0.1 to 5.0 3.0
MINimum UP speed 0 to 65% 16
STEER MAXimum speed 0 to 100% 100
GROUND MODE Tower LIFT UP speed 0 to 100% 42
Tower LIFT DOWN speed 0 to 100% 37
Upper LIFT UP 0 to 100% 50
Upper LIFT DOWN 0 to 100% 60
SWING speed 0 to 100% 60
Upper TELEscope speed 0 to 100% 43
BASKET ROTATE speed 0 to 100% 50
BASKET LEVEL speed 0 to 100% 50
JIB LIFT speed 0 to 100% 25

4150365-3
3121180 – JLG Lift – 6-21

Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3
Configuration Digit Number Description Default Number
MODEL NUMBER: 1 400S 1

1 2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S
MARKET: 0 ANSI USA 0

2 1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 11

3*
* Engine selections vary 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
depending on model selec-
tion. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)
4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)
5 CAT. 3024C: CAT 3024C Diesel (Tier 2)
7 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)
9 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)
10 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)
11 DEUTZ ECM: Engine Control Module - ECM
FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
* This menu item is only visible if 1 110 TEETH: 110 flywheel teeth.
Deutz engine selections 3 or 4 are
selected.
6-22 – JLG Lift – 3121180

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 1

5
1 W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;
engine start can be attempted at any time during pre-glow.
2 W/ STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;

engine start is NOT permitted until pre-glow is finished.
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

6
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or oil
pressure is less than 8 psi.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted 1
7* more than 5 degrees and above elevation; also reduces drive speed to creep.
* Certain market selections
will limit tilt options. 2 4 DEGREES: Reduces maximum speed of all boom functions to creep when tilted more
than 4 degrees and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces maximum speed of all boom functions to creep when tilted more
than 3 degrees and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also disallows tower lift up, tower telescope
out, drive, main telescope out, and main lift up.
5 3 DEGREES + CUT: Reduces maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also disallows tower lift up, tower telescope
out, drive, main telescope out, and main lift up.
Note: Any selections above will light the tilt lamp when a tilted condition occurs and sound
the platform alarm when machine is above elevation.
JIB: 0 NO: No jib installed. 0

8*
* Only visible under certain 1 YES: Jib installed which has up and down movements only.
model selections
4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

9*
* Only visible under certain 1 YES: Four-wheel steer installed.
model selections.
SOFT TOUCH: 0 NO: No soft touch system installed. 0

10*
* Only visible under certain 1 YES: Soft touch system installed.
model selections.
GEN SET/WELDER: 0 NO: No generator installed. 0

11
1 BELT DRIVE: Belt driven setup.
3121180 – JLG Lift – 6-23

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
12*
* Only visible if Gen Set / 1 MOTION CUTOUT: Motion cutout in platform mode only.
Welder Menu selection is not 0.
H & T LIGHTS: 0 NO: No head and tail lights installed. 0

13
1 YES: Head and tail lights installed.
CABLE SWITCH: 0 NO: No broken cable switch installed. 0

14*
* Only visible under certain 1 YES: Broken cable switch installed.
model selections.
* Certain market and model
selections will alter the default
setting.
LOAD SYSTEM: 0 NO: No load sensor installed. 0

15*
* Only visible under certain 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2
model selections. sec OFF).
* Certain market selections will
limit load system options or 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
alter default setting.
sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform
alarm beeps (5 sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).
LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the 1
16* Leveling Platform Module.
* Only visible if Load Sensor
Menu selection is not 0. 1 4 UNDER PLATFORM: Use the EIM for load sensing.
* Market selections will limit
certain load sensor options.
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

17*
* Only visible under certain 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive cutout above elevation.
will limit function cutout options
or alter default setting.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.
6-24 – JLG Lift – 3121180

GROUND ALARM: 0 NO: No ground alarm installed. 0

18*
* Certain market selections will 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
alter default setting.
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
DRIVE: 0 4WD: Four wheel drive. 0

19*
* Only visible under certain 1 2WD: Two wheel drive.
model selections.
2 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.
TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1
20
1 FAHRENHEIT: Fahrenheit unit selection.
LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

21*
* Only visible on 800S models. 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
4150364-14
3121180 – JLG Lift – 6-25

Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1
Configuration Label/ Default

Number Description
Digit Number

1
2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S

2
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
6-26 – JLG Lift – 3121180


Number Description
Digit Number

3*
7 PERKINS 404C (Tier 2)
12 DEUTZ ECM: Engine Control Module - ECM
13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine 0
6 start can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine

start is NOT permitted until pre-glow is finished.
3121180 – JLG Lift – 6-27


Number Description
Digit Number

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 PSI.
will limit tilt options and alter 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
default setting. more than 4 degrees and above elevation; also reduces drive speed to creep.
Note: Any of the selections 3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
above will light the tilt lamp more than 3 degrees and above elevation; also reduces drive speed to creep.
when a tilted condition
occurs and will sound the 4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
platform alarm when the tilted more than 4 degrees and above elevation; also disallows tower lift up, tower tele-
machine is also above ele- scope out, drive, main telescope out and main lift up.
vation.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, tower tele-
scope out, drive, main telescope out and main lift up.

9*
model selections.

10*
model selections.

11*
model selections.

12
6-28 – JLG Lift – 3121180


Number Description
Digit Number
13*
Welder Menu selection is
not 0.

14

15*
model selections.
* Certain market and
model selections will alter
the default setting.

16*
market selections. sec OFF).
will limit load system 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
options or alter default set- sec ON, 2 sec OFF).
ting.
* Only visible if Load Sen-
sor Menu selection is not 0 1 4 UNDER PLATFORM: Use the EIM for load sensing.
and under certain market
selections.
will limit load sensor
options.
3121180 – JLG Lift – 6-29


Number Description
Digit Number

18*
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
will limit function cutout
options or alter default set- 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
ting.

19*
* Certain market selections 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
will alter default setting.

20*
model selections.

21*
* Certain market selections 1 FAHRENHEIT: Fahrenheit unit selection.

22*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.
4150364-18
6-30 – JLG Lift – 3121180

Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present

Number Description
Digit Number

1
2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S

2
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
3121180 – JLG Lift – 6-31


Number Description
Digit Number

3*
7 PERKINS 404C (Tier 2)
12 DEUTZ ECM: Engine Control Module - ECM (Tier 2 and Tier 3)
13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)
14 PERKINS ECM
15 CAT ECM

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
6-32 – JLG Lift – 3121180


Number Description
Digit Number
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine 0
6 start can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine

start is NOT permitted until pre-glow is finished.

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 PSI.
will limit tilt options and alter 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
default setting. more than 4 degrees and above elevation; also reduces drive speed to creep.
Note: Any of the selections 3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
above will light the tilt lamp more than 3 degrees and above elevation; also reduces drive speed to creep.
when a tilted condition
occurs and will sound the 4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
platform alarm when the tilted more than 4 degrees and above elevation; also disallows tower lift up, tower tele-
machine is also above ele- scope out, drive, main telescope out and main lift up.
vation.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, tower tele-
scope out, drive, main telescope out and main lift up.

9*
model selections.

10*
model selections.

11*
model selections.
3121180 – JLG Lift – 6-33


Number Description
Digit Number

12
13*
Welder Menu selection is
not 0.

14

15*
model selections.
* Certain market and
model selections will alter
the default setting.

16*
market selections. sec OFF).
will limit load system 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
options or alter default set- sec ON, 2 sec OFF).
ting.
6-34 – JLG Lift – 3121180


Number Description
Digit Number
* Only visible if Load Sen-
sor Menu selection is not 0 1 4 UNDER PLATFORM: Use the EIM for load sensing.
and under certain market
selections.
will limit load sensor
options.

18*
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
will limit function cutout
options or alter default set- 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
ting.

19*
* Certain market selections 1 DRIVE: Travel alarm sounds when the drive function is active (Option).

20*
model selections.

21*
* Certain market selections 1 FAHRENHEIT: Fahrenheit unit selection.
3121180 – JLG Lift – 6-35


Number Description
Digit Number

22*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.
DRIVE CONTROL: 0 NORMAL: Drive coils are energized from the Ground Module. 2
23
1 PROPULSION: Drive coils are energized from the Propulsion Module.
2 ENHANCED: Drive coils are energized from the Ground Module and the ground side of
the drive coils are brought back to current feedback returns.
CLEARSKY: 0 NO: Clearsky (telematics) option is disabled. 0

24
1 YES: Clearsky (telematics) option is enabled.
CRIBBING OPTION: 0 NO: Cribbing Option is disabled. 0

25
1 YES: Cribbing Option is enabled.
4150364-19
6-36 – JLG Lift – 3121180

NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined
numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
450A Series II
ENGINE SHUTDOWN
STARTER LOCKOUT
GEN SET / WELDER

FLYWHEEL TEETH
GEN SET CUTOUT

MODEL NUMBER
4 WHEEL STEER
GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
JIB
ANSI USA 2 0 7 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
ANSI EXPORT 2 1 7 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
CSA 2 2 7 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
CE 2 3 7 0 1 0 1 2 0 1 0 1 X 2 3 4 5 0 0 0 1 0 1 0 1
AUSTRALIA 2 4 7 0 1 0 1 2 0 1 0 1 X 2 3 4 5 0 0 0 1 0 1 0 1
JAPAN 2 5 7 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
450A Series II
CABLE BREAK SWITCH
HEAD & TAIL LIGHTS
FUNCTION CUTOUT
GROUND ALARM
LEVELING MODE
TEMPERATURE
LOAD SENSOR
LOAD SYSTEM
DRIVE TYPE
ANSI USA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
ANSI EXPORT 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CSA 0 1 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 0 1 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1
AUSTRALIA 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
3121180 – JLG Lift – 6-37

NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined
numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
450AJ Series II
ENGINE SHUTDOWN
STARTER LOCKOUT
GEN SET / WELDER

FLYWHEEL TEETH
GEN SET CUTOUT

MODEL NUMBER
4 WHEEL STEER
GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
JIB
ANSI USA 2 0 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
ANSI EXPORT 2 1 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CSA 2 2 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CE 2 3 11 0 1 0 1 2 0 1 0 1 X 2 3 4 5 1 0 0 1 0 1 0 1
AUSTRALIA 2 4 11 0 1 0 1 2 0 1 0 1 X 2 3 4 5 1 0 0 1 0 1 0 1
JAPAN 2 5 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
450AJ Series II
CABLE BREAK SWITCH
HEAD & TAIL LIGHTS
FUNCTION CUTOUT
GROUND ALARM
LEVELING MODE
TEMPERATURE
LOAD SENSOR
LOAD SYSTEM
DRIVE TYPE
ANSI USA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
ANSI EXPORT 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CSA 0 1 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 0 1 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1
AUSTRALIA 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
6-38 – JLG Lift – 3121180

6.8 SYSTEM TEST 3. Pull out Emergency Stop switch and start engine.
The Control System Incorporates a built-in system test to

check system components and functions.
Test from Platform

1. Position Platform/Ground select switch to Platform.
4. The analyzer screen should read:
2. Plug analyzer into connector at base of platform

control box.
5. Use arrow button to reach SYSTEM TEST and press

Enter. Analyzer prompts you asking if you want to
activate the system test; press Enter again to acti-
vate.
6. Follow flow path in Figure 6-14., System Test Flow
Chart - Platform Tests and go through component
tests. Press ESC key during any part of test to return
to main menu without completing all tests or wait
until all tests are complete. During TEST ALL
INPUTS sequence, the analyzer allows control
switches to be operated and shows if they are
closed (CL) or open (OP).
3121180 – JLG Lift – 6-39

Figure 6-14. System Test Flow Chart - Platform Tests
6-40 – JLG Lift – 3121180

Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the
engine.
1. Set Platform/Ground select switch to Ground.
4. The analyzer screen should read:

2. Plug analyzer into connector inside Ground control
box.
5. Use arrow button to reach SYSTEM TEST. Press

Enter. Analyzer will prompt you asking if you want to
activate system test. Press Enter again to activate.
6. Follow flow path in Figure 6-15., System Test Flow
Chart - Ground Station Tests and go through com-
ponent tests. Press ESC key during any part of test
to return to main menu without completing all tests
or wait until all tests are complete. During TEST ALL
INPUTS sequence, the analyzer allows control
switches to be operated and shows if they are
closed (CL) or open (OP).
3121180 – JLG Lift – 6-41

6-42
– JLG Lift –
Figure 6-15. System Test Flow Chart - Ground Station Tests
3121180
Table 6-5. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Prob-
lems that can be reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from
the platform and ground modules. The system test cannot run in ground mode
unless data is being received from the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed
encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3?), or the tilt sensor has been damaged. Check tilt
sensor.
HOT ENGINE The engine temperature exceeds 100C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other
problems are also detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at
switch on. Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is displayed;
the footswitch MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FSW The two footswitch signals are not changing together, probably because one is
open-circuit. One footswitch signal (“FSW1”) is routed to the power module, the
other (“FSW2”) is routed to the platform module. Check footswitch and wiring.
3121180 – JLG Lift – 6-43


Description
Analyzer Analyzer
TESTING VALVES Indicates valve test is beginning. Each valve is alternately energized and de-ener-
gized; checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope
valves are not tested if TOWER TELE=NO. Jib valves are not tested if JIB = NO.
Extendable axle valves are not tested if EXT AXLES=NO. Four wheel steer valves
are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly.
Check valve wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C Named valve is drawing too much current so is presumed to be short-circuited.
Check valve wiring.
XXXXXXX O/C Named valve is drawing too little current so is presumed to be open-circuit. Check
valve wiring.
CHECKING INPUTS Indicates inputs test is beginning. Every input is checked to ensure that it is in its
“normal” position; function switches should be open, cutout switches should be
closed, joysticks should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any
active cutouts are reported.
In ground mode any non-neutral ground switches is reported; any active cutouts
are reported.
NOTE: Switches not in use (due to the settings of machine digits), are not
checked.
NOTE: Pump pot is checked only for a wire-off condition; it can be at any demand
from creep to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates lamps test is beginning. Each lamp is energized in turn; a prompt asks
for confirmation the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not
checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if
enabled by a machine digit.
TESTING ALARMS Indicates alarms test is beginning. Each alarm is energized in turn; a prompt asks
for confirmation the alarm is sounding.
ENTER must be pressed or clicked to continue test.
NOTE: Platform alarm and horn are only tested in platform mode.
NOTE: Ground alarm is not tested if GROUND ALARM = NO.
6-44 – JLG Lift – 3121180


Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, sys-
tem test ends. If ENTER is pressed or clicked, each operator input is prompted for
in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope
switches are not tested if TOWER TELE=NO. Jib switches are not tested if JIB =
NO. Extendable axle switches are not tested if EXT AXLES=NO. Four wheel steer
switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX Named switch should be closed.
OPEN XXXXXXX Named switch should be opened.
XXXXXXX XXXXXXX TO MAX Named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN Named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX Pump pot should be turned to maximum.
PUMP POT TO MIN Pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could
be a short between two inputs.
TESTS COMPLETE Indicates system test is complete. Problems reported should have been noted
and now be rectified. Press ESC/CANCEL to return to RUN SYSTEM TEST
Analyzer menu.
3121180 – JLG Lift – 6-45

Table 6-6. Machine Diagnostics Parameters
Diagnostics
Parameter Value
Submenu Parameter (Displayed
(Displayed on (Displayed on Analyzer 2nd Description
on Analyzer 2nd Line)
Line)
Analyzer 1st Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if
JOYSTICK TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if
JOYSTICK TYPE = 1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has
two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two
speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL
NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL
NUMBER = 7 or 8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUM-
BER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL
NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Dis-
played if MODEL NUMBER = 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch.
(Displayed if MODEL NUMBER = 7 or 8)
6-46 – JLG Lift – 3121180

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
BOOM:
U LIFT UP/DOWN XXX% Displays upper lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if
JOYSTICK TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if
JOYSTICK TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand
is controlled by the pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE:
demand is controlled by the pump pot
U TELE IN/OUT XXX% Displays upper telescope switch direction & demand. NOTE:
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE:
Not displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is
controlled by the pump pot
Not displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is con-
trolled by the pump pot
Not displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is
controlled by the pump pot
Displayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models
equipped with the Jib Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models

equipped with Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601
(machine digit = 4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
3121180 – JLG Lift – 6-47

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not dis-
played if MODEL NUMBER = 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUM-
BER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ? / ? / ? / FULL or LOW / OK Displays measured fuel level
XXXX rpm Engine RPM
6-48 – JLG Lift – 3121180

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature
FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground
module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform
module.
ABOVE ELEV. OP/CL/YES/NO Displays above elevation cutout switch status or above angle sta-
tus
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if
MODEL NUMBER = 7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL

NUMBER = 7 or 8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if
MODEL NUMBER = 6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER
PROX SWITCHES = 1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if
TOWER PROX SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN
CABLE SWITCH = 1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL =
601 (machine digit = 4)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUM-
BER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is
configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is
configured)
3121180 – JLG Lift – 6-49

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is
configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input
R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch.
Displayed ONLY if MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch.
Displayed ONLY if MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Jib block limit switch status. Not displayed if associated configura-
tion digit = 0
BASKET STOWD YES/NO Status of basket stowed mode. (Displayed if MODEL NUMBER =
7 or 8)
SOFT LIMIT OP/CL Status of soft touch limit switch. Not displayed if associated con-
figuration digit = 0
SOFT O/R OP/CL Status of soft touch override switch. Not displayed if associated
configuration digit = 0
GEN SET/WELDER OP/CL Generator/welder switch input status. Not displayed if associated
LIGHTS OP/CL Head and tail light switch input status. Not displayed if associated
BSK TILT1 XX.X Indicated platform tilt angle. Displayed on models equipped with
Electronic Platform Leveling.
BSK TILT2 XX.X Indicated platform tilt angle. Displayed on models equipped with
Electronic Platform Leveling.
AXLE RET SW OP/CL Status of axle extension user switches. (Displayed if MODEL
NUMBER = 7 or 8)
AXLE EXT SW OP/CL Status of axle retraction user switches. (Displayed if MODEL
NUMBER = 7 or 8)
AXLE LIM SW RET/EXT Status of axle extension limit switches. (Displayed if MODEL
NUMBER = 7 or 8)
DOS LIM SW OP/CL Drive Orientation System Limit Switch status. (Displayed if
DOS O/R SW OP/CL Drive Orientation System Override switch status. (Displayed if
CAPACITY SW 500/1000 Capacity selection switch status. (Displayed if MODEL NUMBER

= 7 or 8)
6-50 – JLG Lift – 3121180

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
osc axle p sw OP/CL Oscillating axle pressure switch status. (Displayed if

OSCILLATING AXLE = 1)
sky welder YES/NO Status of Sky Welder selected during boom sensor calibration.
sky cutter YES/NO Status of Sky Cutter status selected during boom sensor calibra-
tion. (Displayed if MODEL NUMBER = 7 or 8)
sky glazier YES/NO Status of Sky Glazier selected during boom sensor calibration.
sky Bright YES/NO Status of Sky Bright selected during boom sensor calibration.
Pipe Racks YES/NO Status of Pipe Racks selected during boom sensor calibration.
Camera mount YES/NO Status of Camera Mount selected during boom sensor calibra-
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO

(machine digits = 0)
LENGTH OP /CL Measured length, Not displayed if MODEL NUMBER = 7 or 8
ANGLE OP / CL Measured angle, Not displayed if MODEL NUMBER = 7 or 8
WEIGHT XXXX% Percentage of maximum calibrated weight on the platform. An

uncalibrated load cell reads 1000% Displayed if LOAD is not 0 and
LOAD TYPE is 0.
OK/OVERLOADED LSS system status. Displayed if LOAD is not 0 and LOAD TYPE is
1.
3121180 – JLG Lift – 6-51

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Current moment value
(LB-IN) XXXXXXXX Current over moment setpoint.

OVER
(LB-IN) XXXXXXXX Current under moment setpoint.

UNDER
CAL PT XXXXXXXX Under moment value recorded during boom sensor calibration.
UNDER
CAL PT XXXXXXXX Yellow witness mark moment value recorded during boom sensor
WIT YEL calibration.
CAL PT XXXXXXXX Green witness mark moment value recorded during boom sensor
WIT GRN calibration.
CYL PIN X.XXX Current cylinder moment pin ratio of X and Y forces.
RATIO
PIN 0xXXXX Current error flag status of cylinder moment pin.

E FLAGS
sky welder YES/NO Status of Sky Welder selected during boom sensor calibration.
sky cutter YES/NO Status of Sky Cutter selected during boom sensor calibration.
sky glazier YES/NO Status of Sky Glazier selected during boom sensor calibration.
sky Bright YES/NO Status of Sky Bright selected during boom sensor calibration.
Pipe Racks YES/NO Status of Pipe Racks selected during boom sensor calibration.
Camera mount YES/NO Status of Camera Mount selected during boom sensor calibra-
6-52 – JLG Lift – 3121180

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Current indicated boom length in inches.
ANGLE 1 XX.X Current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Current indicated boom length in A/D counts.
A/D ANG1 XXXXX Current indicated boom angle 1 in A/D counts or raw angle if
calibrated.
A/D ANG2 XXXXX Current indicated boom angle 2 in A/D counts or raw angel if
calibrated.
CAN STATISTICS: CAN Statistics as detected by Ground Module
RX/SEC XXX Number of received messages per second
TX/SEC XXX Number of transmitted messages per second
BUS OFF XX Number of bus off occurrences
PASSIVE XX Number of bus passive occurrences
3121180 – JLG Lift – 6-53

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
CALIBRATION DATA
BASKET UP XXX Basket up calibration point
Basket DOWN XXX Basket down calibration point
L FWD DRIVE XXX Left forward drive calibration point
R FWD DRIVE XXX Right forward drive calibration point
L REV DRIVE XXX Left reverse drive calibration point
R REV DRIVE XXX Right reverse drive calibration point
F LT STEER XXX Forward left steer calibration point
F RT STEER XXX Forward right steer calibration point
R LT STEER XXX Reverse left steer calibration point
R RT STEER XXX Reverse right steer calibration point
U LIFT UP XXX Upper lift up calibration point
U LIFT DOWN XXX Upper lift down calibration point
U TELE IN XXX Upper telescope in calibration point
U TELE OUT XXX Upper telescope out calibration point
BM ANG 1 LO XXX Boom angle 1 low calibration point
BM ANG 1 HI XXX Boom angle 1 high calibration point
BM ANG 2 LO XXX Boom angle 2 low calibration point
BM ANG 2 HI XXX Boom angle 2 high calibration point
LEN RETRACT XXX Length sensor retracted calibration point
LEN EXTEND XXXXX Length sensor extended calibration point
LEN WIT XXXXX Witness mark calibration point
LEN SWITCH XXXX Length switch calibration point
6-54 – JLG Lift – 3121180

Diagnostics
Parameter Value
Line)
Analyzer 1st Line)
DATALOG:
ON XXXXhXXm Total controller on (EMS) time
ENGINE XXXXhXXm Engine run time
DRIVE XXXXhXXm Total controller drive operation time
LIFT XXXXhXXm Total controller lift operation time
SWING XXXXhXXm Total controller swing operation time
TELE XXXXhXXm Total controller telescope operation time
MAX TEMP XXC Maximum measured ambient temp.
MIN TEMP XXC Minimum measured ambient temp.
MAX volts XX.XV Maximum measured battery voltage
RENTAL XXXXhXXm Total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at Access Level 2.

ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Ground module software version
GM HW REV XXXX Ground module hardware revision
GM SN XXXXXX Ground module serial number
PM SW PX.X Platform module software version
PM HW REV XXXX Platform module hardware revision
PM SN XXXXXX Platform module serial number
cm sw PX.X Chassis module software version
bm sw PX.X BLAM module software version
c pin SW Cylinder moment load pin transmits software version.
C PIN SN Cylinder moment load pin transmits serial number.
ANALYZER VX.XXXX Analyzer software version
3121180 – JLG Lift – 6-55

Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949
Fault Flash Communicated (Displayed on

Description Priority
Code Analyzer) Fault
None No flash code is indicated for the following help messages. They are intended to hint at a possible problem 1
if the vehicle is not behaving as expected.
EVERYTHING OK The “normal” help message in platform mode
GROUND MODE OK The “normal” help message in ground mode
DRIVING AT CREEP - TILTED Drive speed is limited to creep because the vehicle is tilted.
FSW OPEN A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP - CREEP All function speeds are limited to creep because the creep switch is
SWITCH OPEN open.
RUNNING AT CREEP - TILTED All function speeds are limited to creep because the vehicle is tilted
AND ABOVE ELEVATION and above elevation.
RUNNING AT CUTBACK - ABOVE Drive speed is limited to “ELEVATED MAX” because the vehicle is
ELEVATION above elevation.
TESTS ACTIVE – RECYCLE EMS The system tests have been activated; normal vehicle operation is
TO END not allowed.
1/1 Flash code 1/1 indicates a “sleep” mode.

NOT REQUIRED
2/1 Flash code 2/1 indicates problems with footswitch. 2
FSW FAULTY The two foot switch signals do not agree. EMS recycle required.
KEYSWITCH FAULTY Both platform and ground modes are selected simultaneously
2/2 Flash code 2/2 indicates problems with drive & steer selection. 3
DRIVE JOYSTICK FAULTY Drive joystick center tap is out of valid range or wiper is wire-off.
DRIVE LOCKED – JOYSTICK Drive was selected before and during footswitch closure.
MOVED BEFORE EMS/FSW
FSW INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected.
STEER LOCKED – SELECTED Steer was selected before and during footswitch closure.
BEFORE EMS/FSW
STEER SWITCHES FAULTY Both steer switches are active together.
WAITING FOR FSW TO BE OPEN Footswitch was closed when platform mode was selected.
JOYSTICK FAULTS – CHECK More than one of the drive, lift, and swing joystick center tap or wiper
PLATFORM BOX WIRING voltages is out of range. This is probably due to a short-circuit across
a joystick pot.
6-56 – JLG Lift – 3121180

2/3 Flash code 2/3 indicates problems with boom function selection. 3
LIFT/SWING JOYSTICK FAULTY Lift or swing joystick center tap is out of valid range or wiper is wire-
off.
LIFT/SWING LOCKED - Platform upper lift or swing was selected before and during foot-
JOYSTICK MOVED BEFORE switch closure.
EMS/FSW
PUMP POT FAULTY Pump pot is open-circuit; all platform boom functions except upper
lift & swing will run at creep.
PUMP SWITCHES FAULTY - A boom function (lower lift, telescope, basket level, basket rotate,
CHECK DIAGNOSTICS/BOOM jib) has both directions selected together.
PUMP SWITCHES LOCKED - A platform boom function (lower lift, telescope, basket level, basket
SELECTED BEFORE EMS/FSW rotate, jib) was selected before key switch or footswitch closure.
PUMP SWITCHED LOCKED - A ground boom function (lower lift, telescope, basket level, basket
SELECTED BEFORE EMS rotate, jib) was selected before key switch.
SWING/LIFT JOYSTICK FAULTY Swing joystick center tap is out of valid range or wiper is wire-off.
2/4 Flash code 2/4 indicates that steering digital inputs are faulty.
NOT REQUIRED
2/5 Flash code 2/5 indicates that a function is prevented due to a cutout. 4
BOOM PREVENTED - DRIVE A boom function is selected while a drive function is selected and
SELECTED drive cutout is configured to prevent simultaneous drive & boom
operation.
DRIVE PREVENTED - ABOVE Drive is selected while above elevation and drive cutout is configured
ELEVATION to prevent drive.
DRIVE PREVENTED - BOOM Drive is selected while a boom function is selected and drive cutout is
MOVEMENT SELECTED configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED - TILTED & Drive is selected while tilted and above elevation and tilt is configured
ABOVE ELEVATION to cutout drive.
BOOM PREVENTED – FUNCTION A boom function is selected while function cutout is active and con-
CUTOUT ACTIVE figured to cutout boom functions.
BOOM & DRIVE PREVENTED- Drive or a boom function is selected while function cutout is active
FUNCTION CUTOUT ACTIVE and configured to cutout all functions.
2/7 Flash code 2/7 indicates that the accelerator input is faulty.
NOT REQUIRED
2/8 Flash code 2/8 indicates that the hydraulic filter is being bypassed. 5
RETURN FILTER BYPASSED Hydraulic return filter clogged
CHARGE PUMP FILTER Charge pump filter clogged

BYPASSED
3/1 Flash code 3/1 indicates that a contactor did not close when energized.
NOT REQUIRED
3121180 – JLG Lift – 6-57

3/2 Flash code 3/2 indicates that a contactor did not open when energized.
NOT REQUIRED
3/3 Flash code 3/3 indicates that a driver is short-circuit. 6
ADD DRIVER FAULTS
3/5 Flash code 3/5 indicates a brake pressure problem. 7

NOT REQUIRED
4/2 Flash code 4/2 indicates that the engine is over temperature. NOT REQUIRED 8
4/3 Flash code 4/3 indicates problems with the engine 9
ENGINE TEMP GREATER THAN

130C (266° F)
AIR FILTER BYPASSED Air filter clogged
NO aLTERNATOR OUTPUT The measured battery voltage is less than 12.5 VDC
OIL PRESSURE LESS THAN O.5

BAR (8PSI)
4/4 Flash code 4/4 indicates problems with the battery supply. 7
BATTERY LOW Battery voltage is below 11V. This is a warning - the controller does
not shut down.
BATTERY TOO HIGH - SYSTEM Battery voltage is above 18V. EMS recycle required.
SHUT DOWN
BATTERY TOO LOW - SYSTEM Battery voltage is below 6V. EMS recycle required.
SHUT DOWN
5/5 Flash code 5/5 indicates problems with vehicle engine RPM or the encoder. 8
SPEED SENSOR READING Speed sensor is indicating an impossible number of pulses. This is
INVALID SPEED probably due to a faulty speed sensor.
SPEED INPUT LOST Diesel engine speed input to system has been lost. This is probably
due to wiring problems at ground module or a faulty speed sensor.
ENGINE SPEED DOES NOT Diesel engine governor has stuck. This is probably due to electrical
MATCH COMMAND or mechanical problems with the governor.
6/6 Flash code 6/6 indicates problems with the CAN bus. 10
CAN BUS FAILURE: Ground module or platform module not receiving. This is probably
due to wiring problems between platform and ground modules.
7/7 Flash code 7/7 indicates problems with a motor.

NOT REQUIRED
9/9 Flash code 9/9 indicates problems with the controller. 11
PLATFORM MODULE FAILURE: Platform module V(Low) FET has failed

hwfs CODE 1
GROUND MODULE FAILURE: Ground module V(Low) FET has failed

hwfs CODE 1
6-58 – JLG Lift – 3121180

Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present

None No flash code is indicated for the following help messages. They are intended
1
to hint at a possible problem if vehicle is not behaving as expected.
EVERYTHING OK The “normal” help message in platform mode
GROUND MODE OK The “normal” help message in ground mode
FSW OPEN A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP – CREEP All function speeds are limited to creep because the creep switch is open.
SWITCH OPEN
RUNNING AT CREEP – TILTED AND All boom function speeds are limited to creep because vehicle is tilted and
ABOVE ELEVATION above elevation.
RUNNING AT CUTBACK – OUT OF Drive speed is limited to “ELEVATED MAX” because vehicle is out of transport
TRANSPORT POSITION position.
CHASSIS TILT SENSOR OUT OF The chassis tilt sensor has indicated a tilt angle greater than 19 degrees for
RANGE more than 4 seconds. Not reported during 2 second power-up.
LOAD SENSOR READING UNDER Load sensor is reading 20% or more under calibrated zero point. This fault may
WEIGHT occur if basket is resting on ground. Not reported during 2 second power-up.
ENVELOPE ENCROACHED – Machines with envelope control ONLY. System has detected an envelope
HYDRAULICS SUSPENDED violation
OVER MOMENT – HYDRAULICS SUS- Only occurs on machines with moment control. The system has detected an
PENDED over moment violation.
UNDER MOMENT – HYDRAULICS Machines with moment control ONLY. System has detected an under moment
SUSPENDED violation.
1/1 Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED
2/1 Flash code 2/1 indicates problems with footswitch. 2
FSW FAULTY The two footswitch inputs have read the same state for more than one second.
An EMS cycle is required.
KEYSWITCH FAULTY Platform and ground modes selected simultaneously
3121180 – JLG Lift – 6-59


2/2 Flash code 2/2 indicates problems with drive & steer selection. Except 3
where noted, these faults are not reported during 2 second power-up
sequence.
DRIVE LOCKED – JOYSTICK MOVED Drive selected before and during footswitch closure. Can be reported during
BEFORE FOOTSWITCH power-up sequence.
FSW INTERLOCK TRIPPED Footswitch closed for seven seconds with no function selected. Can be
reported during power-up sequence.
STEER LOCKED – SELECTED Steer was selected before and during footswitch closure.
BEFORE FOOTSWITCH
STEER SWITCHES FAULTY Both steer switches are active at same time.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if Vref voltage is below 8.1 volts. If
Vref is above 7.7 volts, Vref is operating out of tolerance or a short to battery has
occurred.
D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not between
3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt range
around these values where fault may be indicated.
WAITING FOR FSW TO BE OPEN Footswitch closed when platform mode was selected. Can be reported during
power-up sequence.
FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/3 Flash code 2/3 indicates problems with boom function selection. 3
LIFT/SWING LOCKED – JOYSTICK Platform upper lift or swing was selected before and during footswitch closure.
MOVED BEFORE FOOTSWITCH
PUMP SWITCHES FAULTY – CHECK A boom function (lower lift, telescope, basket level, basket rotate, jib) has both
DIAGNOSTICS/BOOM directions selected together.
PUMP SWITCHES LOCKED – A platform boom function (lower lift, telescope, basket level, basket rotate, jib)
SELECTED BEFORE FOOTSWITCH was selected before key switch or footswitch closure.
PUMP SWITCHES LOCKED – A ground boom function (lower lift, telescope, basket level, basket rotate, jib)
SELECTED BEFORE AUX POWER was selected before aux power.
l/s joy. out of range low Resistive joysticks: These faults do not occur.
l/s joy. out of range high Resistive joysticks: These faults do not occur if Vref voltage is below 8.1 volts. If
Vref is above 7.7 volts, Vref is operating out of tolerance or a short to battery has
occurred.
l/s joy. center tap bad Resistive joysticks: These faults occur when center tap voltage is not between
3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt range
around these values where fault may be indicated.
PUMP SWITCHES LOCKED – Hydraulic function switch closed before start switch closed.
SELECTED BEFORE START SWITCH
FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/4 Flash code 2/4 indicates steering digital inputs are faulty.
NOT REQUIRED
6-60 – JLG Lift – 3121180


2/5 Flash code 2/5 indicates a function is prevented due to a cutout. 4
BOOM PREVENTED – DRIVE A boom function is selected while a drive function is selected and drive cutout is
SELECTED configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – ABOVE ELEVA- Drive is selected while above elevation and drive cutout is configured to
TION prevent drive.
DRIVE PREVENTED – BOOM Drive is selected while a boom function is selected and drive cutout is
SELECTED configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – TILTED & Drive is selected while tilted and above elevation and tilt is configured to cutout
ABOVE ELEVATION drive.
JIB SWING PREVENTED – IN 1000# User is trying to jib swing in 1000# mode, which is not allowed.
MODE
CAN DONGLE ATTACHED – HYDRAU- System allows user to operate all hydraulics with very limited restrictions.
LICS NOT RESTRICTED
MODEL CHANGED – HYDRAULICS User changed model number using analyzer. User must cycle power before 11
SUSPENDED – CYCLE EMS hydraulics system will be active again.
BACKUP BLAM COMMUNICATIONS Serial backup communications link to BLAM module is active
ACTIVE
DISCONNECT ANALYZER AND Ground module needs to use RS232 backup communications link to BLAM
CYCLE EMS TO PERFORM BOOM module but an analyzer is connected. Remove analyzer and cycle power
RETRIEVAL
FUNCTIONS LOCKED OUT - PLAT- Major version of platform module does not match major version of ground
FORM MODULE SOFTWARE VER- module
SION IMPROPER
FUNCTIONS LOCKED OUT - CHASSIS Major version of chassis module does not match major version of ground
MODULE SOFTWARE VERSION module
IMPROPER
FUNCTIONS LOCKED OUT - BLAM Major version of BLAM module does not match major version of ground
MODULE SOFTWARE VERSION module
IMPROPER
2/7 Flash code 2/7 indicates that accelerator input is faulty.
NOT REQUIRED
2/8 Flash code 2/8 indicates a problem with a hydraulic filter. Not reported 5
during 2 second power-up.
RETURN FILTER BYPASSED Hydraulic return filter clogged
charge pump filter bypassed Charge pump filter clogged
3/1 Flash code 3/1 indicates a contactor did not close when energized.
NOT REQUIRED
3/2 Flash code 3/2 indicates a contactor did not open when energized.
NOT REQUIRED
3121180 – JLG Lift – 6-61


3/3 Flash code 3/3 indicates a driver problem. All driver faults are detected in 6
a similar manner. Open circuit faults are detected when analog feedback
reads too high and output is commanded off. Short to ground is detected
when analog feedback reads low and output is commanded on. Short to
battery is detected when analog feedback reads Vbat and output is
commanded off. Not reported during 2 second power-up. An EMS cycle
is required.
RIGHT FORWARD DRIVE PUMP Machines with a chassis module ONLY.
SHORT TO GROUND
SHORT TO BATTERY
OPEN CIRCUIT
RIGHT REVERSE DRIVE PUMP Machines with a chassis module ONLY.
SHORT TO GROUND
RIGHT REVERSE DRIVE PUMP Machines with a chassis module ONLY.
SHORT TO BATTERY
RIGHT REVERSE DRIVE PUMP OPEN Machines with a chassis module ONLY.
CIRCUIT
LEFT FORWARD DRIVE PUMP Machines with a chassis module ONLY.
SHORT TO GROUND
LEFT FORWARD DRIVE PUMP Machines with a chassis module ONLY.
SHORT TO BATTERY
LEFT FORWARD DRIVE PUMP OPEN Machines with a chassis module ONLY.
CIRCUIT
LEFT REVERSE DRIVE PUMP SHORT Machines with a chassis module ONLY.
TO GROUND
LEFT REVERSE DRIVE PUMP SHORT Machines with a chassis module ONLY.
TO BATTERY
LEFT REVERSE DRIVE PUMP OPEN Machines with a chassis module ONLY.
CIRCUIT
ALTERNATOR/ECM POWER SHORT
TO GROUND
HOUR METER SHORT TO GROUND
HOUR METER SHORT TO BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT
HORN SHORT TO BATTERY
AUX POWER SHORT TO GROUND
AUX POWER OPEN CIRCUIT
AUX POWER SHORT TO BATTERY
GLOW PLUG SHORT TO GROUND Machines with glowplugs configured ONLY.
GLOW PLUG OPEN CIRCUIT Machines with glowplugs configured ONLY
GLOW PLUG SHORT TO BATTERY Machines with glowplugs configured ONLY
LP LOCK SHORT TO GROUND Machines with dual-fuel engines ONLY.
LP LOCK OPEN CIRCUIT Machines with dual-fuel engines ONLY.
6-62 – JLG Lift – 3121180


LP LOCK SHORT TO BATTERY Machines with dual-fuel engines ONLY.
LP START ASSIST SHORT TO Machines with dual-fuel engines ONLY.
GROUND
LP START ASSIST OPEN CIRCUIT Machines with dual-fuel engines ONLY.
LP START ASSIST SHORT TO BAT- Machines with dual-fuel engines ONLY.
TERY
MAIN DUMP SHORT TO GROUND
MAIN DUMP OPEN CIRCUIT
MAIN DUMP SHORT TO BATTERY
PARKING BRAKE SHORT TO
GROUND
PARKING BRAKE OPEN CIRCUIT
PARKING BRAKE SHORT TO BAT-
TERY
START SOLENOID SHORT TO Machines with diesel engines ONLY.
GROUND
START SOLENOID OPEN CIRCUIT Machines with diesel engines ONLY.
START SOLENOID SHORT TO BAT- Machines with diesel engines ONLY.
TERY
MAIN LIFT APU SHORT TO GROUND 1250AJP ONLY.
MAIN LIFT APU OPEN CIRCUIT 1250AJP ONLY.
MAIN LIFT APU SHORT TO BATTERY 1250AJP ONLY.
MAIN LIFT PILOT PRESSURE FAIL- 1250AJP ONLY.
URE
NO MAIN LIFT PILOT PRESSURE 1250AJP ONLY.
MAIN LIFT PILOT PRESSURE 1250AJP ONLY.
SWITCH FAILURE
STEER DUMP SHORT TO GROUND
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO BATTERY
TWO SPEED SHORT TO GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO BATTERY
GROUND ALARM SHORT TO Machines with ground alarm configured ONLY.
GROUND
GROUND ALARM OPEN CIRCUIT Machines with ground alarm configured ONLY
GROUND ALARM SHORT TO BAT- Machines with ground alarm configured ONLY
TERY
GEN SET/WELDER SHORT TO Machines with a generator configured ONLY.
GROUND
GEN SET/WELDER OPEN CIRCUIT Machines with a generator configured ONLY.
GEN SET/WELDER SHORT TO BAT- Machines with a generator configured ONLY
TERY
HEAD TAIL LIGHT SHORT TO Machines with headlights option configured ONLY.
GROUND
3121180 – JLG Lift – 6-63


HEAD TAIL LIGHT OPEN CIRCUIT Machines with headlights option configured ONLY
HEAD TAIL LIGHT SHORT TO BAT- Machines with headlights option configured ONLY
TERY
BASKET UP OVERRIDE SHORT TO Machines with electronic leveling systems ONLY.
GROUND
BASKET UP OVERRIDE OPEN CIR- Machines with electronic leveling systems ONLY.
CUIT
BASKET UP OVERRIDE SHORT TO Machines with electronic leveling systems ONLY.
BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY
BASKET DOWN SHORT TO GROUND
BASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN OVERRIDE SHORT Machines with electronic leveling systems ONLY.
TO GROUND
BASKET DOWN OVERRIDE OPEN Machines with electronic leveling systems ONLY.
CIRCUIT
BASKET DOWN OVERRIDE SHORT Machines with electronic leveling systems ONLY.
TO BATTERY
TOWER LIFT APU VALVE STUCK 1250AJP ONLY.
OPEN
TOWER LIFT ENABLE STUCK OPEN 250AJP ONLY.
TOWER LIFT ENABLE SHORT TO 250AJP ONLY.
GROUND
TOWER LIFT ENABLE OPEN CIRCUIT 250AJP ONLY.
TOWER LIFT ENABLE SHORT TO 250AJP ONLY.
BATTERY
TOWER TELESCOPE APU SHORT TO 250AJP ONLY.
GROUND
TOWER TELESCOPE APU OPEN CIR- 250AJP ONLY.
CUIT
TOWER TELESCOPE APU SHORT TO 250AJP ONLY.
BATTERY
BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO BATTERY
BASKET LEFT SHORT TO GROUND
BASKET RIGHT SHORT TO GROUND
BASKET RIGHT OPEN CIRCUIT
BASKET RIGHT SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB DOWN SHORT TO GROUND
6-64 – JLG Lift – 3121180


JIB DOWN OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
TOWER UP SHORT TO GROUND
TOWER UP OPEN CIRCUIT
TOWER UP SHORT TO BATTERY
TOWER DOWN SHORT TO GROUND
TOWER DOWN OPEN CIRCUIT
TOWER DOWN SHORT TO BATTERY
TOWER IN SHORT TO GROUND
TOWER IN OPEN CIRCUIT
TOWER IN SHORT TO BATTERY
TOWER OUT SHORT TO GROUND
TOWER OUT OPEN CIRCUIT
TOWER OUT SHORT TO BATTERY
MAIN IN SHORT TO GROUND
MAIN IN OPEN CIRCUIT
MAIN IN SHORT TO BATTERY
MAIN OUT SHORT TO GROUND
MAIN OUT OPEN CIRCUIT
MAIN OUT SHORT TO BATTERY
LIFT UP DUMP SHORT TO GROUND
LIFT UP DUMP OPEN CIRCUIT
LIFT UP DUMP SHORT TO BATTERY
LIFT DOWN HOLDING SHORT TO
GROUND
LIFT DOWN HOLDING OPEN CIRCUIT
LIFT DOWN HOLDING SHORT TO
BATTERY
LIFT PILOT VALVE SHORT TO Machines with gravity lift down ONLY.
GROUND
LIFT PILOT VALVE SHORT TO BAT- Machines with gravity lift down ONLY.
TERY
LIFT PILOT VALVE OPEN CIRCUIT Machines with gravity lift down ONLY.
LIFT DOWN AUX VALVE SHORT TO Machines with gravity lift down ONLY.
GROUND
LIFT DOWN AUX VALVE SHORT TO Machines with gravity lift down ONLY.
BATTERY
3121180 – JLG Lift – 6-65


LIFT DOWN AUX VALVE OPEN CIR- Machines with gravity lift down ONLY.
CUIT
TOWER LIFT APU SHORT TO 1250AJP ONLY.
GROUND
TOWER LIFT APU OPEN CIRCUIT 1250AJP ONLY.
TOWER LIFT APU SHORT TO BAT- 1250AJP ONLY.
TERY
MAIN LIFT ENABLE SHORT TO 1250AJP ONLY.
GROUND
MAIN LIFT ENABLE OPEN CIRCUIT 1250AJP ONLY.
MAIN LIFT ENABLE SHORT TO BAT- 1250AJP ONLY.
TERY
TOWER TELE APU VALVE STUCK 1250AJP ONLY.
OPEN
TOWER TELE ENABLE STUCK OPEN 1250AJP ONLY.
TOWER TELE APU SHORT TO 1250AJP ONLY.
GROUND
TOWER TELE APU OPEN CIRCUIT 1250AJP ONLY.
TOWER TELE APU SHORT TO BAT- 1250AJP ONLY.
TERY
PVG VALVE SHORT TO GROUND 1250AJP ONLY.
PVG VALVE OPEN CIRCUIT 1250AJP ONLY.
PVG VALVE SHORT TO BATTERY 1250AJP ONLY.
FOX SPARE OUTPUT SHORT TO Fox machines ONLY.
GROUND
FOX SPARE OUTPUT SHORT TO BAT- Fox machines ONLY.
TERY
FOX SPARE OUTPUT OPEN CIRCUIT Fox machines ONLY.
HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation. It may be reported
during self test.
RESTRICTED TO TRANSPORT – Machines with electrically released oscillating axles configured ONLY. A short
AXLE LOCKOUT VALVE STB OR OC to battery or open circuit has been detected on axle lockout valve and machine
is restricted to transport position.
RESTRICTED TO TRANSPORT – Machines with electrically released oscillating axles configured ONLY. A short
PARKING BRAKE STB to battery has been detected on parking brake valve and machine is restricted
to transport position.
6-66 – JLG Lift – 3121180


3/4 Flash code 3/4 indicates a driver problem on a platform valve block valve 6
driver. All driver faults are detected in a similar manner. Open circuit
faults are detected when analog feedback reads too high and output is
commanded off. Short to ground is detected when analog feedback
reads low and output is commanded on. Short to battery is detected
when analog feedback reads Vbat and output is commanded off. Not
reported during 2 second power-up. An EMS cycle is required.
BASKET UP SHORT TO BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY OR Machines with electronic basket leveling ONLY.
OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN SHORT TO GROUND
bASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY Machines with electronic basket leveling ONLY.
OR OPEN CIRCUIT
BASKET LEFT SHORT TO BATTERY
BASKER LEFT SHORT TO GROUND
BASKET LEFT OPEN CIRCUIT
BASKET RIGHT SHORT TO BATTERY
BASKET RIGHT SHORT TO GROUND
BASKET RIGHT OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
PLATFORM CONTROL VALVE SHORT Machines with electronic basket leveling ONLY.
TO BATTERY
PLATFORM CONTROL VALVE SHORT Machines with electronic basket leveling ONLY.
TO GROUND
PLATFORM CONTROL VALVE OPEN Machines with electronic basket leveling ONLY.
CIRCUIT
3/5 Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED
4/2 Flash code 4/2 indicates that the engine is over temperature. NOT
REQUIRED
3121180 – JLG Lift – 6-67


4/3 Flash code 4/3 indicates engine problems. These faults are not reported 9
during 2 second power-up sequence except where noted.
HIGH ENGINE TEMP Occurs when engine temperature is above 117 degrees Celsius for Ford and
130 degrees Celsius for Deutz engines.
AIR FILTER BYPASSED Air filter clogged
NO ALTERNATOR OUTPUT Engine running for 15 seconds or more and battery voltage still below 11.5
volts.
LOW OIL PRESSURE If a Deutz engine is configured, oil pressure is below 8 PSI and engine has been
running for at least 10 seconds. If a Ford engine is configured, Ford ECM has
reported a low oil pressure fault.
OIL PRESSURE SHORT TO BATTERY If a Deutz engine is configured, this indicates oil pressure sensor is reading
above 6.6 volts.
OIL PRESSURE SHORT TO GROUND If a Deutz engine is configured, this indicates oil pressure sensor is reading
below 0.1 volts for more than 5 seconds. This fault is not detected during crank.
COOLANT TEMPERATURE SHORT If a Deutz engine is configured, this indicates coolant temperature is reading
TO GROUND below 0.1 volts.
FORD FAULT CODE ## All Ford fault codes except 63 are simply passed through from the FORD ECM.
They only occur if a Ford engine is selected in machine configuration digits.
Can be reported during power-up sequence.
ENGINE FAULT CODE : All J1939 CANBUS ECMs report fault messaging in this format. SPN number
###(SPN) :###(FMI) represents what is broken and FMI number represents how component is bro-
ken.
FORD FAULT CODE UNKNOWN An unrecognized Ford ECM fault code has been received. Can be reported
during power-up sequence.
485 COMMUNICATIONS LOST Ford engine ONLY. No responses received from ECM for 2.5 seconds. Can be
reported during power-up sequence.
FUEL SENSOR SHORT TO BATTERY Fuel sensor reading above 4.3 volts.
FUEL SENSOR SHORT TO GROUND Fuel sensor is reading below 0.2 volts.
WRONG ENGINE SELECTED – ECM Engine Control Module (ECM) detected on the CANBUS. Only applies when
PRESENT non-CANBUS engine setups are configured.
ECM CAN COMMUNICATION LOST Engine is configured to have a CANBUS controlled engine and JLG system
does not detect an ECM. This fault can be the result of power lost to ECM or a
break in CANBUS communications connection from ECM to JLG system.
4/4 Flash code 4/4 indicates problems with battery supply. Not reported 7
during 2 second power-up.
BATTERY LOW Battery voltage is below 11V for more than 5 seconds. Fault is not detected
during crank. This is a warning – controller does not shut down.
BATTERY TOO HIGH – SYSTEM SHUT Battery voltage is above 16V. EMS recycle required.
DOWN
BATTERY TOO LOW – SYSTEM SHUT Battery voltage is below 9V.
DOWN
6-68 – JLG Lift – 3121180


4/5 Flash code 4/5 indicates problems with the S-D CAN based PVG valves
currently used on the 1250AJP only. 7
MAIN LIFT PVG COMMUNICATIONS CAN communications lost with Main Lift PVG valve.
tower lift pvg communications CAN communications lost with Tower Lift PVG valve.
tOWER TELESCOPE PVG COMUNI- CAN communications lost with Tower Telescope PVG valve.
CATIONS
MAIN LIFT PVG internal fault Main boom lift pvg valve internal fault.
tower lift pvg internal fault Tower boom lift pvg valve has an internal fault.
tOWER TELESCOPE PVG internal fault Tower boom telescope pvg valve internal fault.
MAIN LIFT PVG VALVE HIGH VOLT- Main boom lift pvg valve high excitation voltage.
AGE
TOWER LIFT PVG VALVE HIGH VOLT- Tower boom lift pvg valve high excitation voltage.
AGE
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve high excitation voltage.
HIGH VOLTAGE
MAIN LIFT PVG VALVE LOW VOLTAGE Main boom lift pvg valve low excitation voltage.
TOWER LIFT PVG VALVE LOW VOLT- Tower boom lift pvg valve low excitation voltage.
AGE
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve low excitation voltage.
LOW VOLTAGE
MAIN LIFT PVG VALVE STUCK NEU- Main boom lift pvg valve spool stuck in neutral position.
TRAL
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in neutral position.
NEUTRAL
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in neutral position.
STUCK NEUTRAL
MAIN LIFT PVG VALVE STUCK Main boom lift pvg valve spool stuck in extended position.
EXTENDED
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in extended position.
EXTENDED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in extended position.
STUCK EXTENDED
MAIN LIFT PVG VALVE STUCK Main boom lift pvg valve spool stuck in retracted position.
RETRACTED
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in retracted position.
RETRACTED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in retracted position.
STUCK RETRACTED
MAIN LIFT PVG VALVE OBSTRUCTED Main boom lift pvg valve spool could not achieve command.
TOWER LIFT PVG VALVE Tower boom lift pvg valve spool could not achieve command.
OBSTRUCTED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool could not achieve command.
OBSTRUCTED
3121180 – JLG Lift – 6-69


MAIN LIFT PVG VALVE COMMAND Main boom lift pvg valve received invalid control system command.
IMPROPER
TOWER LIFT PVG VALVE COMMAND Tower boom lift pvg valve received invalid control system command.
IMPROPER
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve received invalid control system command.
COMMAND IMPROPER
MAIN LIFT PVG VALVE TIMEOUT Main boom lift pvg valve has not received a position command in 250mS.
TOWER TELESCOPE PVG VALVE Tower boom lift pvg valve has not received a position command in 250mS.
TIMEOUT
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg has not received a position command in 250mS.
TIMEOUT
MAIN LIFT PVG VALVE SETUP FAULT Main boom lift pvg valve setup data is incorrect. Requires valve calibration.
TOWER LIFT PVG VALVE SETUP Incorrect tower boom lift pvg valve setup data. Requires valve calibration.
FAULT
TOWER TELESCOPE PVG VALVE Incorrect tower boom telescope pvg valve setup data. Requires valve calibra-
SETUP FAULT tion.
MAIN LIFT PVG VALVE SENT UNREC- Main boom lift pvg valve sent unrecognized fault.
OGNIZED FAULT
TOWER LIFT PVG VALVE SENT Tower boom lift pvg valve sent an unrecognized fault.
UNRECOGNIZED FAULT
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve sent an unrecognized fault.
SENT UNRECOGNIZED FAULT
MAIN LIFT PVG VALVE PARAMETERS Main lift pvg valves spool data is incorrect. Requires valve calibration.
INCORRECT
TOWER LIFT PVG VALVE PARAME- The tower lift pvg valves spool data is incorrect. Requires valve calibration.
TERS INCORRECT
TOWER TELESCOPE PVG VALVE The tower telescope pvg valves spool data is incorrect. Requires valve calibra-
PARAMETERS INCORRECT tion.
MAIN LIFT PVG VALVE LOCATION Main lift pvg valve was hosed wrong or wiring incorrect during calibration.
IMPROPER
TOWER LIFT PVG VALVE LOCATION Tower lift pvg valve was hosed wrong or wiring incorrect during calibration.
IMPROPER
TOWER TELESCOPE PVG VALVE Tower telescope pvg valve was hosed wrong or wiring incorrect during calibra-
LOCATION IMPROPER tion.
MAIN LIFT PVG VALVE WIRING Power wire for main lift pvg valve not wired to that valve.
INCORRECT
TOWER LIFT PVG VALVE WIRING Power wire for tower lift pvg valve not wired to that valve.
INCORRECT
TOWER TELESCOPE PVG VALVE Power wire for tower telescope pvg valve not wired to that valve.
WIRING INCORRECT
5/5 Flash code 5/5 indicates problems with vehicle engine RPM or the 8
encoder. Not reported during 2 second power-up.
SPEED SENSOR READING INVALID Diesel engines only. RPM pickup indicating a speed greater than 4000 RPM or
SPEED approximately 8875 Hz.
SPEED INPUT LOST Diesel engines only. No RPM detected and oil pressure input reading above 8
PSI for more than three seconds. This is probably due to wiring problems at
ground module or a faulty speed sensor.
6-70 – JLG Lift – 3121180


6/6 Flash code 6/6 indicates problems with the CAN bus. 10
PLATFORM CAN COMMUNICATIONS Ground module or platform module not receiving CAN messages. This is
LOST probably due to wiring problems between platform and ground modules.
BLAM CAN COMMUNICATIONS LOST Machines with a BLAM ONLY. Ground module or BLAM module not receiving
CAN messages. This is probably due to wiring problems between BLAM and
ground modules.
CHASSIS CAN COMMUNICATIONS Machines with a chassis module ONLY. Ground module or chassis module is
LOST not receiving CAN messages. This is probably due to wiring problems between
chassis and ground modules.
CYLINDER LOAD PIN CAN COMMUNI- Machines with a cylinder load pin ONLY. Ground module or cylinder load pin
CATIONS LOST not receiving CAN messages. This is probably due to wiring problems between
cylinder load pin and ground module.
EXCESSIVE CAN BUS COMMUNICA- More than 500 Bus Off or more than 500 Bus Passive conditions detected by
TION ERRORS Ground Module in current power cycle.
MAIN ANGL1 CAN COMMUNICA- Control system lost CAN communications with main boom angle sensor #1
TIONS LOST (1250AJP only)
MAIN ANGL2 CAN COMMUNICA- Control system lost CAN communications with main boom angle sensor #2
TIONS LOST (1250AJP only)
7/7 Flash code 7/7 indicates problems with a motor.
NOT REQUIRED
8/1 Flash code 8/1 indicates problems with the Chassis tilt detection system. 10
CHASSIS TILT SENSOR NOT CALI- Leveling (zeroing) calibration not performed for chassis tilt sensor.
BRATED
8/2 Flash code 8/2 indicates problems with the platform load sensing sys- 10
tem.
LOAD SENSOR NOT CALIBRATED Calibration procedure not been performed for load sensor.
3121180 – JLG Lift – 6-71


8/3 Flash code 8/3 indicates problems with the Basket Leveling system. 10
BASKET LEVELING CRACKPOINT UP Only occurs on machines with electronic leveling systems. Indicates that the
NOT CALIBRATED basket up valve crackpoint has not been calibrated
BASKET LEVELING CRACKPOINT Only occurs on machines with electronic leveling systems. Indicates that the
DOWN NOT CALIBRATED basket down valve crackpoint has not been calibrated
BASKET LEVELING SENSOR 1 NOT Only occurs on machines with electronic leveling systems. Indicates that the
ZERO CALIBRATED primary basket leveling tilt sensor has not been calibrated.
BASKET LEVELING SENSOR 1 ZERO Only occurs on machines with electronic leveling systems. Indicates that the
OUT OF RANGE primary basket leveling tilt sensor zero is outside of the allowable range
BASKET LEVELING SENSOR 1 Only occurs on machines with electronic leveling systems. Indicates that the
SHORT TO BATTERY primary basket leveling tilt sensor is shorted to battery. An EMS cycle is
required.
SHORT TO GROUND OR OPEN CIR- primary basket leveling tilt sensor is either shorted to ground or is not con-
CUIT nected. An EMS cycle is required.
BASKET LEVELING SENSOR 2 NOT Only occurs on machines with electronic leveling systems. Indicates that the
ZERO CALIBRATED secondary basket leveling tilt sensor is not zero calibrated.
BASKET LEVELING SENSOR 2 ZERO Only occurs on machines with electronic leveling systems. Indicates that the
OUT OF RANGE secondary basket leveling system tilt sensor zero is outside the allowable
range.
SHORT TO BATTERY secondary basket leveling tilt sensor is shorted to battery. An EMS cycle is
required.
SHORT TO GROUND OR OPEN CIR- secondary basket leveling tilt sensor is either shorted to ground or not con-
CUIT nected. An EMS cycle is required.
BASKET LEVELING TILT REFERENCE Only occurs on machines with electronic leveling systems. Indicates that the
1 OUT OF RANGE reference voltage for the primary basket leveling tilt sensor is outside the
expected range (4.9 to 5.1 volts). An EMS cycle is required.
BASKET LEVELING TILT REFERENCE Only occurs on machines with electronic leveling systems. Indicates that the
2 OUT OF RANGE reference voltage for the secondary basket leveling tilt sensor is outside the
expected range. (4.9 to 5.1 volts). An EMS cycle is required.
BASKET LEVELING TILT SENSOR Only occurs on machines with electronic leveling systems. Indicates that the
DIFFERENCE TOO GREAT basket leveling tilt readings both appear to be good but their measurements do
not agree within a specified adjustable tolerance. An EMS cycle is required.
BASKET LEVELING SYSTEM TIME- Only occurs on machines with electronic leveling systems. Indicates that the
OUT basket was not able to maintain the desired level within an adjustable range for
and adjustable time
BASKET LEVELING OVERRIDE ON User has forced basket leveling on through Access Level 0.
BASKET LEVELING OVERRIDE OFF User has forced basket leveling off through Access Level 0.
BASKET LEVELING TILT SENSOR 1 Communications have been lost with a serial leveling sensor. Only on 1200S
COMMUNICATIONS LOST and 1350S models. An EMS cycle is required.
BASKET LEVELING TILT SENSOR 2 Communications have been lost with a serial leveling sensor. Only on 1200S
COMMUNICATIONS LOST and 1350S models. An EMS cycle is required.
6-72 – JLG Lift – 3121180


8/4 Flash code 8/4 indicates problems with the envelope system. Only occur 10
on machines with envelope control.
BOOM ANGLE SENSOR DISAGREE- The boom angle sensors are reporting angles that differ too greatly. An EMS
MENT cycle is required.
BOOM LENGTH SWITCH FAILED The boom length switch inputs are reporting the same state. An EMS cycle is
required.
BOOM LENGTH SWITCH/SENSOR The boom length switch and sensor differ in their reports of extended or
DISAGREEMENT retracted. An EMS cycle is required.
BOOM LENGTH SENSOR NOT The boom length sensor has not detected a change in length while the user is
DETECTING LENGTH CHANGE commanding telescope. An EMS cycle is required.
BOOM LENGTH SENSOR OUT OF Indicates that the voltage for the boom length sensor is above the expected
RANGE HIGH range.
BOOM LENGTH SENSOR OUT OF Indicates that the voltage for the boom length sensor is below the expected
RANGE LOW range.
BOOM LENGTH SENSOR VALUE OUT Indicates the length reported for the boom length sensor is above the expected
OF RANGE HIGH range. An EMS cycle is required.
BOOM LENGTH SENSOR VALUE OUT Indicates the length reported for the boom length sensor is below the expected
OF RANGE LOW range. An EMS cycle is required.
BOOM ANGLE SENSOR #1 COMMU- Boom angle sensor #1 lost communications with the BLAM. An EMS cycle is
NICATIONS FAULT required.
BOOM ANGLE SENSOR #2 COMMU- Boom angle sensor #2 lost communications with the BLAM. An EMS cycle is
NICATIONS FAULT required.
ANGLE SENSOR #1 INVALID ANGLE An EMS cycle is required.
ANGLE SENSOR #2 INVALID ANGLE An EMS cycle is required.
WRONG TELE RESPONSE The boom telescope is contrary to the user command
WRONG LIFT RESPONSE The boom lift is contrary to the user command
TOWER ANGLE SENSOR DISAGREE- The tower angle sensors are reporting angles that differ too greatly. An EMS
MENT cycle is required.
TOWER LENGTH SENSOR DIS- The tower length sensors are reporting angles that differ too greatly. An EMS
AGREEMENT cycle is required.
MAIN ANGLE SENSOR DISAGREE- The main boom angle sensors are reporting angles that differ too greatly. An
MENT EMS cycle is required.
BOOM LENGTH SENSOR #1 OUT OF Reported from the BLAM, indicates tower length sensor one value is out of
RANGE HIGH range high.
BOOM LENGTH SENSOR #1 OUT OF Reported from the BLAM, indicates tower length sensor one value is out of
RANGE LOW range low.
BOOM LENGTH SENSOR #2 OUT OF Reported from the BLAM, indicates tower length sensor two value is out of
RANGE HIGH range high.
BOOM LENGTH SENSOR #2 OUT OF Reported from the BLAM, indicates tower length sensor two value is out of
RANGE LOW range low.
TWR LENGTH SENSOR NOT Tower tele is being commanded and the length sensors are not changing
DETECTING LENGTH CHANGE value.
TWR LENGTH MOVEMENT WITHOUT Tower length is changing without a tower tele command
CMD
TWR LENGTH SENSOR ONE VALUE This fault is reported by the Ground module when the length sensor value is
OUT OF RANGE HIGH outside the constant data limit
3121180 – JLG Lift – 6-73


TWR LENGTH SENSOR ONE VALUE This fault is reported by the Ground module when the length sensor value is
OUT OF RANGE LOW outside the constant data limit
TWR LENGTH SENSOR TWO VALUE This fault is reported by the Ground module when the length sensor value is
OUT OF RANGE HIGH outside the constant data limit
TWR LENGTH SENSOR TWO VALUE This fault is reported by the Ground module when the length sensor value is
OUT OF RANGE LOW outside the constant data limit
TWR ANGL1 INVALID ANGLE Tower boom angle sensor #1 out of range
TWR ANGL2 INVALID ANGLE Tower boom angle sensor #2 out of range
INVALID ANGLE SENSOR #1 MODEL Wrong tower angle sensor Mfgr. Installed on a 1250AJP (Must be a Rieker, not
Spectron)
INVALID ANGLE SENSOR #2 MODEL Wrong tower angle sensor Mfgr. Installed on a 1250AJP (Must be a Rieker, not
Spectron)
MAIN ANGL1 INVALID ANGLE Main boom angle sensor #1 out of range
MAIN ANGL2 INVALID ANGLE Main boom angle sensor #2 out of range
MAIN ANGLE SENSOR NOT DETECT- The main boom is being commanded to move and the main angle sensors are
ING ANGLE CHANGE not detecting any movement
MAIN ANGLE MOVEMENT WITHOUT The main boom angle is changing without a main lift command
CMD
WRONG TWR TELE RESPONSE The tower telescope is moving in the opposite direction the user is command-
ing.
WRONG TWR LIFT RESPONSE The tower lift is moving in the opposite direction the user is commanding
TWR CYL ANGLE SENSOR OUT OF The tower cylinder angle sensor is below 4721 A/D counts
RANGE LOW
TWR CYL ANGLE SENSOR OUT OF The tower cylinder angle sensor is above 29535 A/D counts.
RANGE HIGH
TWR CYL ANGLE NOT DETECTING The cylinder angle is not changing during a tower lift up/down user command.
ANGLE CHANGE
TWR CYL ANGLE MOVEMENT WITH- The cylinder angle is changing without a tower lift command
OUT CMD
MAIN TRN ANGLE SW FAILED The system detected a disagreement of the N.O. vs N.C. contacts on the main
boom angle switch.
TWR TRN SW DISAGREEMENT The system detected a disagreement between the tower boom length switch
and the tower length sensors.
TRN DUAL CAP SWITCHES BAD The system detected both the Dual capacity and the transport switches are
bad.
TRN DUAL CAP BAD TRANSITION The system detected that the Dual capacity or the transport switches changed
state out of order.
MAIN TRN LEN SW DISAGREEMENT The system detected a disagreement between the main boom transport length
switches.
DCAP LEN SW DISAGREEMENT The system detected a disagreement between the main boom dual capacity
length switches.
MAIN BOOM TRN ANGLE SW/SEN- The system detected a disagreement between the main boom transport angle
SOR DISAGREEMENT switch and the main boom angle sensors.
CYL ANGLE SENSOR/SW DISAGREE- The system detected a disagreement of the tower angle input from the BLAM
MENT and the tower cylinder angle sensor.
6-74 – JLG Lift – 3121180


8/5 Flash code 8/5 indicates problems with the moment or load pin system. 10
Only occur on machines with moment or load pin control. An EMS cycle
is required.
MOMENT PIN HORIZONTAL FORCE The horizontal force is out of the allowed range.
OUT OF RANGE
MOMENT PIN VERTICAL FORCE OUT The vertical force is out of the allowed range.
OF RANGE
LOAD PIN HORIZONTAL FORCE OUT The horizontal force is out of the allowed range.
OF RANGE
LOAD PIN VERTICAL FORCE OUT OF The vertical force is out of the allowed range.
RANGE
MOMENT PIN SENSOR FAULT The moment pin has reported a fault flag.
LOAD PIN SENSOR FAULT The load pin has reported a fault flag.
NEW MOMENT PIN DETECTED A moment pin was detected on the system different from the one used to cali-
FAULT brate the machine.
NEW LOAD PIN DETECTED FAULT A load pin was detected on the system different from the one used to calibrate
the machine.
3121180 – JLG Lift – 6-75


8/6 Flash code 8/6 indicates steering system problem. An EMS cycle is 10
required except as noted.
RESTRICTED TO TRANSPORT – OSC Only occurs on machines with electrically released oscillating axles config-
AXLE PRESS SW DISAGREEMENT ured. The oscillating axle pressure switch indicates pressure while the
machine is not driving or does not indicate pressure while the machine is driv-
ing and the machine is restricted to transport position.
AXLE EXT STB OR OC A short to battery or open circuit was detected on the axles extension valve.
AXLE EXT STG A short to ground was detected on the axles extension valve.
AXLE RET STB OR OC A short to battery or open circuit was detected on the axles retract valve.
AXLE RET STG A short to ground was detected on the axles retract valve.
RT FNT STEER RT STB OR OC A short to battery or open circuit has been detected on the right front steer right
valve.
RT FNT STEER RT STG A short to ground has been detected on the right front steer right valve.
RT FNT STEER LT STB OR OC A short to battery or open circuit has been detected on the right front steer left
valve.
RT FNT STEER LT STG A short to ground has been detected on the right front steer left valve.
LT FNT STEER RT STB OR OC A short to battery or open circuit has been detected on the left front steer right
valve.
LT FNT STEER RT STG A short to ground has been detected on the left front steer right valve.
LT FNT STEER LT STB OR OC A short to battery or open circuit has been detected on the left front steer left
valve.
LT FNT STEER LT STG A short to ground has been detected on the left front steer left valve.
RT REAR STEER RT STB OR OC A short to battery or open circuit has been detected on the right rear steer right
valve.
RT REAR STEER RT STG A short to ground has been detected on the right rear steer right valve.
RT REAR STEER LT STB OR OC A short to battery or open circuit has been detected on the right rear steer left
valve.
RT REAR STEER LT STG A short to ground has been detected on the right rear steer left valve.
LT REAR STEER RT STB OR OC Left rear steer right valve short to battery or open circuit.
LT REAR STEER RT STG Left rear steer left valve short to ground.
LT REAR STEER LT STB OR OC Left rear steer left valve short to battery or open circuit.
LT REAR STEER LT STG Left rear steer left valve short to ground.
FRONT LEFT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
FRONT RIGHT WHEEL FAULT – Steering angle sensor decoupled.
CHECK MOUNTING
REAR LEFT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
REAR RIGHT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
FRONT LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears.
FRONT RIGHT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears.
6-76 – JLG Lift – 3121180


REAR LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears.
REAR RIGHT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears.
FRONT LEFT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
FRONT LEFT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
FRONT RIGHT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
FRONT RIGHT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
REAR LEFT WHEEL SENSOR OUT OF Steering angle sensor short to ground or open circuit detected.
RANGE LOW
REAR LEFT WHEEL SENSOR OUT OF Steering angle sensor short to battery detected.
RANGE HIGH
REAR RIGHT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
REAR RIGHT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
8/7 Flash code 8/7 indicates new main angle sensors 10
NEW MAIN ANGL1 SENSOR System detected a different main angle #1 sensor than it was calibrated with.
DETECTED (1250AJP only.)
NEW MAIN ANGL2 SENSOR System detected a different main angle #2 sensor than it was calibrated with.
DETECTED (1250AJP only.)
3121180 – JLG Lift – 6-77


9/9 Flash code 9/9 indicates problems with the controller or the user dis- 11
abling safety systems from Access Level 0.
PLATFORM MODULE SOFTWARE Platform module code is too old to support the EIM or BPE load sensor and
UPDATE REQUIRED machine is configured to use one of these two sensors. PM code must be
updated to a newer version.
GROUND MODULE CONSTANT DATA Ground module has old constant data that is not compatible with current
UPDATE REQUIRED ground module software. GM constant data must be updated to a newer
version. An EMS cycle is required.
HIGH RESOLUTION A2D FAILURE – ADS1213 chip in the platform module has stopped asserting its interrupt
INTERRUPT LOST (DRDY) line for some reason. An EMS cycle is required.
HIGH RESOLUTION A2D FAILURE- ADS1213 has needed to be reset 3 or more times. An EMS cycle is required.
REINIT LIMIT
PLATFORM MODULE FAILURE: hwfs Platform module V(Low) FET has failed. An EMS cycle is required.
CODE 1
GROUND MODULE FAILURE: hwfs Ground module V(Low) FET has failed. An EMS cycle is required.
CODE 1
GROUND SENSOR REF VOLTAGE Seven volt reference voltage for joysticks, sensors, etc. is out of range. Not
OUT OF RANGE reported during 2 second power-up. An EMS cycle is required.
GROUND MODULE FAILURE: hIGH Hardware based high side driver cutout circuit fault. An EMS cycle is required.
SIDE DRIVER CUTOUT FAULTY
PLATFORM SENSOR REF VOLTAGE These faults occur when the seven volt reference voltage used for the joy-
OUT OF RANGE sticks, sensors, etc goes out of range. Not reported during 2 second power-up.
An EMS cycle is required.
EEPROM FAILURE – CHECK ALL SET- EEPROM critical failure. Personalities, machine configuration digits, etc may
TINGS be reset to default values and should be checked. An EMS cycle is required.
CHASSIS TILT SENSOR NOT GAIN Chassis tilt sensor calibration information has been lost. Machine indicates it is
CALIBRATED tilted at all times. This calibration data is programmed into unit at the factory.
CHASSIS TILT SENSOR GAIN OUT OF Chassis tilt sensor calibration has become corrupted. This calibration data is
RANGE programmed into unit at the factory.
ENVELOPE CONTROL DISABLED Machines with envelope control ONLY. User has forced envelope control off
with analyzer from Access Level 0.
MOMENT CONTROL DISABLED Only occurs on machines with envelope control ONLY. The user has forced
moment control off with the analyzer from Access Level 0.
STEER SENSORS NOT CALIBRATED Machines with a chassis module ONLY. Steer sensors require calibration.
BOOM SENSORS NOT CALIBRATED Machines with a BLAM module ONLY. Boom sensors require calibration.
LIFT CRACKPOINTS NOT CALI- 1200S and 1350S machines ONLY. Lift valves require a calibration.
BRATED
TELESCOPE CRACKPOINTS NOT 1200S and 1350S machines ONLY. Telescope valves require a calibration.
CALIBRATED
DRIVE CRACKPOINTS NOT CALI- 1200S and 1350S machines ONLY. Drive valves require a calibration.
BRATED
6-78 – JLG Lift – 3121180


BLAM SENSOR SUPPLY OUT OF Supply voltage for boom angle sensors is above expected range. An EMS
RANGE HIGH cycle is required.
BLAM SENSOR SUPPLY OUT OF Supply voltage for boom angle sensors is below expected range. An EMS cycle
RANGE LOW is required.
LENGTH SENSOR REF VOLTAGE Supply voltage for boom length sensors is above expected range. An EMS
HIGH cycle is required.
LENGTH SENSOR REF VOLTAGE Supply voltage for boom length sensors is below expected range. An EMS
LOW cycle is required.
BLAM HIGH RES A/D FAILURE High resolution analog to digital converter in the BLAM module has failed. An
EMS cycle is required.
CHASSIS SENSOR SUPPLY OUT OF Supply voltage for chassis sensors is below expected range. An EMS cycle is
RANGE LOW required.
CHASSIS SENSOR SUPPLY OUT OF Supply voltage for chassis sensors is above expected range. An EMS cycle is
RANGE HIGH required.
BLAM BACKUP COMMUNICATIONS Backup communications link to the BLAM failed test at startup.
LINK FAULTY
BLAM BACKUP COMMUNICATIONS Backup communications link to the BLAM module was activated but could not
LOST - HYDRAULICS SUSPENDED establish/maintain communications with the BLAM.
4150461-E
3121180 – JLG Lift – 6-79

NOTES:
6-80 – JLG Lift – 3121180

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL Polarity
This section contains basic electrical information and Getting a negative voltage or current reading when
schematics for locating and correcting most operating expecting a positive reading frequently means leads are
problems. If a problem develops which is not presented in reversed. Check what reading is expected, location of sig-
this section or not corrected by listed corrective actions, nal, and leads are connected to device under test cor-
obtain technically qualified guidance before proceeding rectly. Check lead on "COM" port goes to ground or
with any maintenance. negative side of signal and lead on other port goes to pos-
itive side of signal.
7.1 MULTIMETER BASICS
Scale
A wide variety of multimeters or Volt Ohm Meters (VOM)
can be used for troubleshooting your equipment. This M = Mega = 1,000,000 * (Displayed Number)
section shows diagrams of a common, digital VOM con- k = kilo = 1,000 * (Displayed Number)
figured for several different circuit measurements. Instruc-
tions for your VOM may vary. Please consult meter m = milli = (Displayed Number) / 1,000
operator’s manual for more information. μ = micro = (Displayed Number) / 1,000,000
Grounding Example: 1.2 k = 1200 

Example: 50 mA = 0.05 A
"Grounding the meter" means to take the black lead
(connected to COM (common) or negative port) and Voltage Measurement
touch it to a good path on negative side of voltage source.
Backprobing
"Backprobe" means to take the measurement by access-
ing a connector’s contact on the same side as the wires,
on back of the connector. Readings can be done while
maintaining circuit continuity. If connector is the sealed
type, great care must be taken to avoid damaging seal
around the wire. It is best to use probes or probe tips spe-
cifically designed for this technique, especially on sealed
connectors. Whenever possible, insert probes into the
side of the connector so the test checks both terminals of
the connection. It is possible to inspect a connection
within a closed connector by backprobing both sides of a
connector terminal and measuring resistance. Do this
after giving each wire a gentle pull to ensure wires are still
attached to the contact and contacts are seated in the
connector.
Min/Max
Use of "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
while alone. For example, you can read voltage applied to Figure 7-1. Voltage Measurement (DC)
a solenoid when it is only operational while a switch, far
from the solenoid and meter, is held down. • If meter is not auto ranging, set it to correct range
(See multimeter’s operation manual).
• Use firm contact with meter leads.
3121180 – JLG Lift – 7-1

Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to

enable audible continuity testing.
• Circuit power must be OFF before testing continuity.
Figure 7-2. Resistance Measurement
• Disconnect component from circuit before testing.
• Test meter and leads by touching leads together.
Resistance should read a short circuit (very low
resistance). • First test meter and leads by touching leads
together. Meter should produce an audible alarm,
• Circuit power must be OFF before testing resistance.
indicating continuity.
• Disconnect component from circuit before testing.
• If meter is not auto ranging, set it to correct range
(See multimeter’s operation manual).
7-2 – JLG Lift – 3121180

Current Measurement 7.2 APPLYING SILICONE DIELECTRIC

COMPOUND TO ELECTRICAL
CONNECTIONS
NOTE: Do NOT apply dielectric grease to the following con-
nections:
• Main Boom Rotary sensor connections (on Celesco

Sensor).
• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electri-
cal connections except those listed above for the follow-
ing reasons:
• To prevent oxidation at mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Sili-
cone grease should not be applied to connectors with
external seals.
Figure 7-4. Current Measurement (DC)
1. To prevent oxidation, silicone grease must be
• Set up meter for expected current range. packed completely around male and female pins on
• Connect meter leads to correct jacks for current inside of connector before assembly. This is most
range selected. easily achieved using a syringe.
• If meter is not auto ranging, set it to correct range NOTE: Over a period of time, oxidation increases electrical
(See multi meter’s operation manual). resistance at the connection, causing circuit failure.
2. To prevent shorting, silicone grease must be packed
around each wire where they enter the connector
housing. Also, silicone grease must be applied at
the joint where male and female connectors come
together. Any other joints (around strain reliefs, etc.)
where water could enter, connector should also be
sealed.
NOTE: This condition is especially common when machines

are pressure washed since washing solution is much
more conductive than water.
3. Anderson connectors for battery boxes and battery

chargers should have silicone grease applied to
contacts only.
NOTE: Curing-type sealants can also be used to prevent

shorting and are less messy, but make future pin
removal more difficult.
3121180 – JLG Lift – 7-3

7.3 AMP CONNECTOR Assembly

Check wedge lock is in the open, or as-shipped position
Applying Silicone Dielectric Compound to (See Figure 7-5.). Proceed as follows:
AMP Connectors
Silicone Dielectric Compound must be used on AMP
connections for the following reasons:
• To prevent oxidation at mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to electrical connectors.
1. To prevent oxidation and low level conductivity, sili-
cone dielectric grease must be packed completely
around male and female pins on inside of connector
after mating housing to the header. This is easily
achieved by using a syringe to fill the header with sil-
icone dielectric compound, to a point just above top
of male pins inside the header. When assembling
housing to the header, it is possible housing will
become air locked and prevent housing latch from
engaging. Figure 7-5. Connector Assembly Figure 1
2. Pierce one of the unused wire seals to allow

trapped air inside housing to escape. 1. Push contact straight into appropriate circuit cavity
as far as it will go (See Figure 7-7.).
3. Install a hole plug into this and/or any unused wire
seal that has silicone dielectric compound escaping 2. Pull contact wire with a force of 1 or 2 lbs. to be sure
from it. retention fingers hold contact (See Figure 7-7.).
Figure 7-6. AMP Connector
7-4 – JLG Lift – 3121180

Figure 7-7. Connector Assembly Figure 2
3. After all required contacts are inserted, close wedge 4. Slide wedge lock into housing until flush with
lock to its locked position. Release locking latches housing (See Figure 7-9.).
by squeezing them inward (See Figure 7-8.).
3121180 – JLG Lift – 7-5

Figure 7-10. Connector Disassembly
Disassembly Wedge Lock

1. Insert a 3/16" (4.8 mm) wide screwdriver blade between The wedge lock has slotted openings in the forward, or
mating seal and one of the red wedge lock tabs. mating end. These slots accommodate circuit testing in the
field by using a flat probe such as a pocket knife. DO NOT
2. Pry wedge lock to the open position. use a sharp point such as an ice pick. Service - Voltage
3. While rotating wire back and forth over a half turn Reading
(1/4 turn in each direction), gently pull wire until
contact is removed.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
NOTE: Wedge lock should never be removed from housing
for contact insertion or removal.
It is common practice in electrical troubleshooting to
probe wires by piercing insulation with a sharp point. This
practice should be discouraged when dealing with the
AMPSEAL plug assembly, or any other sealed connector
system. Resulting pinholes in insulation allows moisture to
invade the system by traveling along wire strands. This
nullifies effectiveness of connector seals and could result
in system failure.
7-6 – JLG Lift – 3121180

Figure 7-11. Connector Installation
3121180 – JLG Lift – 7-7

7.4 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal
1. Remove wedgelock (A) using needlenose pliers or a

1. Grasp crimped contact about 25mm behind contact hook shaped wire to pull wedge straight out.
barrel.
NOTE: Hold rear seal in place. Removing contact may dis-
2. Hold connector with rear grommet facing you. place seal.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly 2. Gently pull wire and contact out of connector (C),
locked in place. while at the same time releasing locking finger by
moving it away from contact with a screwdriver (B).
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular
wedges are not oriented. They may go in either way.
NOTE: Receptacle shown - use same procedure for plug.
7-8 – JLG Lift – 3121180

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal
1. Grasp contact about 25mm behind contact crimp

1. With rear insert toward you, snap appropriate size
barrel.
extractor tool over wire of contact to be removed.
2. Hold connector with rear grommet facing you.
2. Slide tool along into the insert cavity until it engages
3. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm it is
3. Pull contact-wire assembly out of connector.
locked in place.
Figure 7-17. HD/HDP Unlocking Contacts

Figure 7-15. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: Insert sealing plugs in unused wire cavities for full
environmental sealing
3121180 – JLG Lift – 7-9

Figure 7-18. Electrical Components Installation - Sheet 1
7-10 – JLG Lift – 3121180

Figure 7-19. Electrical Components Installation - Sheet 2
3121180 – JLG Lift – 7-11

NOTE: This Schematic covers machines built prior to S/N 1300000979.
Figure 7-20. Electrical Schematic - Sheet 1 of 4
7-12 – JLG Lift – 3121180

1870144G
3121180 – JLG Lift – 7-13

NOTE: This Schematic covers machines built prior to S/N 1300000979.
7-14 – JLG Lift – 3121180

1870144G
3121180 – JLG Lift – 7-15

NOTE: This Schematic covers machines built from S/N 1300000979 to S/N 1300002604.
Figure 7-24. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6
7-16 – JLG Lift – 3121180

1870191 G
3121180 – JLG Lift – 7-17

NOTE: This Schematic covers machines built from S/N 1300000979

to S/N 1300002604.
7-18 – JLG Lift – 3121180

1870191 G
3121180 – JLG Lift – 7-19

NOTE: This Schematic covers machines built from

S/N 1300000979 to S/N 1300002604.
7-20 – JLG Lift – 3121180

1870191 G
3121180 – JLG Lift – 7-21

PLATFORM WORK LIGHTS OPTION #1

GREEN
RED
BLACK
10/3
RED
BLACK
RED
20 AMP
PLATFORM WORK LIGHTS OPTION #2
GREEN BLACK
RED
BLACK GREEN
10/3 STROBE LIGHT
RED 15 YEL/BLK(18) 15 BLU/ORN 52-11 1

BLACK 15 AMP
PLATFORM BOX 15 AMP 2
C.B.
BLU/ORN 52-11
MTB
SELECT
SWITCH MTB
MAIN TELE IN BROWN 13-1 5 19 ORN/RED 49-4 PLATFORM EMS
ALARM EMS YEL/RED
MAIN TELE OUT BROWN 14-1 6 YEL/RED
20 BLACK 13 ORN/BLK 13 2 B1 YEL/RED
GRAY 24-1 2-5 2-5
ROTATE RIGHT 7 2-4 (12)
33 GRAY 23-1 3 LEFT ROTATE 4
ROATE LEFT GRAY 23-1 8 YEL/RED YEL/RED
34 GRAY 24-1 4 RIGHT ROTATE 10 ORN(12) 10 1 B YEL/RED
LEVEL UP PINK 25-1 9 2-2(12) 2-2(12)
21 PINK 25-1 2 UP LEVEL 3 2-1(12)
LEVEL DOWN PINK 26-1 10
22 PINK 26-1 1 DOWN LEVEL
J7 (BLACK)
JIB UP BLUE 27-1 11

25 BLUE 27-1 5 UP JIB
JIB DOWN BLUE 28-1 12
YEL/RED 2-3(16)
26 BLUE 28-1 6 DOWN JIB YEL/RED
FUEL SELECT YEL/RED
BLU/ORN 52-20 33 23 BLACK 7 2-30-4
UPPER 2-1-3
Ref.V RED/ORN 4 RED/WHT 55-30 34 (12)
PUMP 28 VALVE
WIPER
POTENTIOMETER GREEN 6 RED/WHT 55-31 35 29 450ASII
GND BRN/BLK 5 BLACK 13 10 VOLT REF. ONLY
SPARE 30
CREEP 2 ORN/RED 49-11 32 13 INPUT ANALOG 86 85
19 14 GND 87a
87
15 YEL/RED 2-37 20 31 CAN HI RED (18) 3 RED (18) 3
ORN/YEL
BLU/YEL
21 30 CAN LO BLACK (18) BLACK (18) 2

2
BLACK 0-1
22 32 CAN SHIELD 1 SHIELD 1
23 EMS PTF TO MTB output YEL/RED 2-3-1
3 4 ORANGE (18) 4
J1 (WHITE)
3 24 1 GND MODE
YEL/RED 2-30-1
ORN 55-52 2 PTF EMS
25
YEL/RED 2-10 18 27
YEL/RED 2-1-1(12)
TOWER UP TAN 5-1 1 35 BLACK TO SOFT TOUCH IND.
FOOTSWITCH 2
J1-19
TOWER DOWN TAN 6-1 2 8 ORN/RED 49-70 7 BLACK
TOWER TELE IN BROWN 15-1 3 4 ORN/RED 49-71 8 WHITE 7 GREEN 6 YELLOW (18) 6
TOWER TELE OUT BROWN 16-1 4
17 WHITE 8
CRAB STEER YELLOW 55-16 16 JIB BLOCK LIMIT SW 8 HOLE PLUG
6 BLACK
COORDINATED STEER YELLOW 55-17 17 14 HOLE PLUG 14
18 YEL/RED 2-63 3 WHT BLK 4 SOFT
26 R
WHT 5 TOUCH 17 HOLE PLUG 17
14 7 ORN/RED 49-69 6 BLK L
START SWITCH WHT/YEL 48-1 19 HOLE PLUG 19
9 BLU/ORN 52-4 1
AUX POWER BRN/ORN 53-1 15 GENERATOR
5 BLU/ORN 52-3 2
ENGINE SPEED WHT/YEL 48-5 28 16 BLACK (12) 16
11 ORN/RED 49-72 9
TWO SPEED ORANGE 55-46 27
HORN 12 ORN/RED 49-73 10 12 RED (12) 12
BLU/ORN 52-1 31
SOFT TOUCH OVERIDE 15 ORN/RED 49-75 12 11 BLU/BLK 11
ORN/RED 49-40 29
HEAD/TAIL LIGHTS 16 ORN/RED 49-74 11
BLU/ORN 52-12 30 9 RED/BLK (18) 9
24
7 BROWN (18) 7
30
5 BLUE (18) 5
TILT ORN/RED 49-3 6
SYSTEM DISTRESS BRN/WHT 47-12 8
J8 (BLACK)
GND FROM GND MODULE

FOOTSWITCH/ENABLE YEL/RED 2-21 7 1 BLACK (12)
GND EMS
CREEP ORN/RED 49-15 9 2 YEL/RED 2-1-2
CABLE SERVICE ORN/RED 49-101 10 IGN POWER

CONNECTOR
J2 (GRAY)
OVERLOAD ORN/RED 49-100 11

226KG/500# CAPACITY RED/YEL 54-2 12
YEL/RED 2-4 (16)
453KG/1000# CAPACITY RED/YEL 54-3 13 RED (18) CAN HI
CAN LO
DRIVE ORIENTATION ORN 55-51 14 BLACK (18)
CAN SHIELD
GENERATOR ON BLU/ORN 52-4-1 15 YEL/RED 2-63
ORN/RED 49-86
GLOW PLUG WHT/YEL 48-6 17 DUAL CAPACITY
YEL/RED 2-1-99 (16)
DRIVE DISABLED BRN/WHT 47-14 19 MACHINES ONLY

YEL/RED 2-1-98
UPRIGHT TILTED ORN/RED 49-102 20 TRANSPORT LENGTH

SWITCH (CE ONLY)
BLACK 18
6 SWING 4 ORN/RED 49-62 5 WHT
FUEL GAGE
BRN/WHT 47-4
RED 1-2
FULL 35 ORN/RED 49-77

BRN/WHT 47-3 23 5 WHITE 5K
NLY 3/4
SO 1
J5 (WHITE)
BRN/WHT 47-2 RED/BLU ORN/RED 49-76 3 ORN/RED 49-60 2 BLK

4 00 1/2 24
1/4 BRN/WHT 47-1 4 GRN/YEL BLK WHT
22
2 GREEN TOWER ELEVATION 450ASII
BLACK 25
600 A/AJ, ONLY
LY BLACK 25
LOW FUEL LAMP ON 3 BROWN LIFT
0S
(N/A WITH FUEL GAGE) 40 BRN/WHT 47-13 21 7 BLACK OR BLU/YEL
C
A
B
5K
SEE SHEET 2
TO J7-35 2
SOFT TOUCH ORN/RED 49-42 16
DRIVE ORIENTATION 1 BLUE
SEE SHEET 2
ORN 55-50 4 5 WHT/GRN LEFT

OVERRIDE SWITCH STEER
33 6 WHT/YEL RIGHT
J6 (BLACK)
14 YEL/RED 2-36 32 4
34 2 BLUE
RED ORN/RED 49-92 26 1 RED OR WHT/RED
11
GREEN 10 ORN/RED 49-91 28 3 BROWN
WHITE 9 ORN/RED 49-90 29 7 BLACK
ORN/RED 49-89 27 DRIVE
BLACK/SHIELD 8
3
31
5
ANALYZER TRANSMIT
ANALYZER RECEIVE
ANALYZER GROUND
ANALYZER POWER
NOTE: This Schematic covers machines built S/N 1300002604 to Present.

1 2 3 4
Figure 7-30. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 6
7-22 – JLG Lift – 3121180

GROUND CONTROL BOX
30 AMP
RED 1-2(10)
TO BATTERY NEG.
+12 VDC
24 OUTPUT
YEL/RED 2-40-9 WHEN ON
MAIN TELE IN BROWN 13-2 7 GROUND 17 BLACK HORN GND
MAIN TELE OUT BROWN 14-2 30 CONTROLS 2 BLU/ORN 52-2 HORN OUTPUT
ROTATE RIGHT GRAY 24-2 18
10 GRAY 23-3 LEFT ROTATE
ROTATE LEFT GRAY 23-2 6
PINK 25-2 21 GRAY 24-3 RIGHT ROTATE
LEVEL UP 17
5 PINK 25-3 UP LEVEL
LEVEL DOWN PINK 26-2 5
7 PINK 26-3 DOWN LEVEL
START SWITCH WHT/YEL 48-1 4
12 BLUE 27-3 UP JIB
AUX POWER/ENABLE BRN/ORN 53-2 16
23 BLUE 28-3 DOWN JIB
20 13 RED/WHT 50-1 MAIN DUMP
9
J4 (BLUE)
1 YELLOW 55-2 STEER DUMP

BLUE 27-2
JIB UP 19 31 RED/WHT 50-6 FLOW CONTROL
JIB DOWN BLUE 28-2 8 33 TAN 5-3 UP TOWER LIFT
MAIN LIFT UP TAN 3-2 23
J2 (GRAY)
32 TAN 6-3 DOWN TOWER LIFT
MAIN LIFT DOWN TAN 4-2 33 3 BROWN 15-3 IN TOWER TELE.
WHITE 22-2 35
SWING RIGHT 15 BROWN 16-3 OUT TOWER TELE
SWING LEFT WHITE 21-2 34
4 BROWN 13-3 IN MAIN TELE
TOWER LIFT UP TAN 5-2 10 BROWN 14-3
16 OUT MAIN TELE
TOWER LIFT DOWN TAN 6-2 21
8 YELLOW 10-1 RIGHT FRONT STEER
BROWN 15-2 11
TOWER TELE IN 19 YELLOW 9-1 LEFT FRONT STEER
BROWN 16-2 22 +12 VDC
TOWER TELE OUT 11 TAN 3-3 UP MAIN LIFT
YEL/RED 2-40 25 OUTPUT
22 TAN 4-3 DOWN MAIN LIFT
WHEN ON
1 GROUND 35 WHITE 22-3 RIGHT SWING
HOURMETER CONTROLS 34 WHITE 21-3
BRN/WHT 47-8 12 LEFT SWING
ENGINE LOW 9 YELLOW 12-1 RIGHT REAR STEER
OIL PRESSURE BRN/WHT 47-5-1 29
20 YELLOW 11-1 LEFT REAR STEER
ENGINE HIGH
TEMPERATURE BRN/WHT 47-6-1 28 14 BLACK HEAD/TAIL LIGHT OUTPUT
NO CHARGE BRN/WHT 47-8-1 26 30 BLACK 87
87a
27 29 BLACK ALARM 85
BLACK (10)
86
PLATFORM 27 BLU/ORN 52-10 30 14 GA.
OVERLOAD ORN/RED 49-100 14 FUSE LINK
26 BLU/ORN 52-12 12 BLU/ORN 52-12 RED 1-1 (12)
BOOM MALFUNCTION 13 18 BLACK 0-5 13
INDICATOR BRN/WHT 47-15 15 24
(800A/AJ ONLY) 25 UNITS WITH 4 LED
28 SPARE-GND FUEL GAGE IN
2 PLATFORM.
25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) 6
GLOW PLUG WHT/YEL 48-6 3 6 BLACK SENSOR (GROUND) 25
BLACK 31 6 UNITS WITH LOW
32 1 FUEL LIGHT IN
PLATFORM
GND FROM BATTERY 2
1 3 ORANGE 7-2 DRIVE FORWARD
MTB EMS input
2
J8 (BLACK)
GND TO PLATFORM 6 ORANGE 8-2 DRIVE REVERSE

BLACK (12) 3 23 ORANGE 55-45 BRAKE
MTB EMS TO PLATFORM
YEL/RED 2-1-2(12) 4 20 ORANGE 55-47 2-SPEED
5 BLACK 0-4
18 BLACK 0-2
27 BLACK 0-3
4 AUXILIARY POWER
8 NOTE: NOT ALL BLACK GROUND WIRES PUMP
RED (18) CAN HI 9 ARE NUMBERED ON ALL MODELS MOTOR
13 M
CAN LO 12
BLACK (18) 24
J1 (WHITE)
CAN SHIELD 13 BRN/ORN 53-2

18
YEL/RED 2-3-1 PTF EMS 1 28 YEL/RED ANALYZER POWER 1
YEL/RED 2-21 FOOTSWITCH 29 ORN/RED 49-91 ANALYZER RECEIVE 2
15
YEL/RED 2-30 MTB MODE SELECT 3 30 ORN/RED 49-90 ANALYZER TRANSMIT 3
PLATFORM MODE INPUT ANALYZER GROUND 4
YEL/RED 2-2-1 2 31 BLACK 0-2
MTB MODE OUTPUT
YEL/RED 2-30-1 14 10 SEE SHEET 2
POWERMITE FOR 7500 W
9 11 GENERATOR
14 GENERATOR
23
25 15 87 87a
5 85 14 GA.
22 BLU/ORN 52-5 14 BLU/ORN 52-5 86
DRIVE ORIEN. 33 30 FUSE LINK
PROX. SW 16
ORN/RED 49-106 35
24
J7 (BLACK)
BLK 10 ORN/RED 49-66 4

25
WHT 9 YEL/RED 2-62 16
BLK 8 ORN/RED 49-65 7 26
YEL/RED 2-61 26 7
WHT 7
CAPACITY LENGTH SWITCH 21
10
CAPACITY ANGLE SWITCH 17
BLK 6 ORN/RED 49-64 29 34
32
30 B+
33
WHT 1 YEL/RED 2-60 11
19
MAIN BOOM ELEVATION 35
ALL MODELS 8
28
BROWN 2 ORN/RED 49-87 32 2 12 VDC
4 BATTERY
4 1 BLACK 3 ORN/RED 49-88 12
8
31 9
3
J3 (BLACK)
34 6
22 7
6 13
CAT ENGINE ONLY WHT/YEL 17 14
3
21 10
11
19 1
20 5
27 12
1870215 D
3121180 – JLG Lift – 7-23

RED 1-1(10) STARTER

STARTER
MOTOR
FUSIBLE LINK
MOTOR
SOL. SOL.
STARTER FAN STARTER
MOTOR MOTOR MOTOR
CAT ENGINE
400S, 450A/AJ
B+
WHT/YEL 48-12(12)
WHT/YEL 48-12(12)
14 GA. FUSE LINK

D+
WHT/YEL 48-10 (12)
REGULATOR
GLOW PLUGS
14 GA. FUSE LINK

GLOW PLUGS
FLYWHEEL
SPEED GLOW
PICKUP PLUG
START SOL. FLYWHEEL
SOL. W SPEED GLOW
PICKUP PLUG
START SOL.
SOL.
THROTTLE
ACTUATOR
C B A 87a 87
RED 1-3 (12)
THROTTLE
COOLANT TEMP. ACTUATOR
86 85 SENSOR C B A
11
30
BRN/WHT 47-21
ORN/RED 49-51
WHT/YEL 48-9
WHT/YEL 48-3
ORN/RED 49-50
OIL PRESSURE
ORN/RED 49-54
BLACK 0-5
BRN/WHT 47-8
BLACK
SENSOR
BRN/WHT 47-6
FUEL ON
BLACK
WHT/YEL 48-9
ORN/RED 49-51
WHT/YEL 48-3
ORN/RED 49-50
ORN/RED 49-54
SOLENOID
BLACK
WHT/YEL 48-6
BRN/WHT 47-5
ORN/RED 49-53
J1-16
J1-12
J7-27
J1-11
J1-1
J1-15
J1-16
J1-12
J1-14
J1-11
J1-7
J1-1
J1-8
J1-8
J7-27
120 OHM
RESISTOR
FUEL ON 87 87a
ALTERNATOR
RELAY 86 85 EXCITATION
30 RELAY
400S/SJ, 450A/AJ CAT ONLY
YEL/RED 2-6-2 87 87a
86 85
30
CAT ENGINE
BLACK 0-6
YEL/RED 2-4-1 ONLY
YEL/RED 2-6-2
BLACK 0-1
YEL/RED 2-4-1 (12)

J1-17
GM ENGINE
J1-10
J1-19 B
PLATFORM
GM ENGINE GROUND
CONNECTOR #1
SEE SHT 3
SELECT
SWITCH
N
P
A
C
F
BRN/WHT 47-8-2
BRN/WHT 47-8-1
BLACK (18)
RED (18)
BRN/WHT 47-8
CAN LO
CAN HI
AUXILIARY
CAN SHIELD
WHT/YEL 48-8
SOLENOID
BLACK
WHT/YEL 48-3
STARTER
YEL/RED 2-1-99 (16)
MOTOR
SOL. SEE
SHT 3
STARTER
MOTOR
C
B
A
SEE SHT 1
FUEL IGN POWER

C-5
J1-11
PUMP CONNECTOR
SEE SHT 1
NOTE: This Schematic covers machines built S/N 1300002604 to Present.
7-24 – JLG Lift – 3121180

RECTIFER
FUEL
PUMP B+ FUSIBLE
RED 1-1(10)
2 LINK
1 STATOR
CAT ENGINE
BLACK
WHT/YEL 48-8
600A, 600S, 800A
RED 1-1(10)
STARTER ALTERNATOR
FUEL PUMP RELAY MOTOR
(LOCATED IN M.T.B.) SOL.
ALTERNATOR WITH PLUG CONNECTOR REGULATOR
87a 87 SENSING AND
B+ FUSIBLE STARTER
MOTOR SWITCHING
LINK CIRCUITS
86 P D+
30 85 1
BLACK 0-6
IG
STATOR 2
RED 1-10
BRN/WHT 47-20
WHT/YEL 48-13 (8)
WHT/YEL 48-12(12)
MIC L
BRN/WHT 47-8-1
3
BRN/WHT 47-8
ALTERNATOR
WHT/YEL 48-15
BRN/WHT 47-21 GLOW PLUGS
BATTERY CABLE (1 GA.)

GLOW
START
PLUG
COOLANT TEMP. SOL.
SOL.
SENSOR FUEL ON
SOLENOID
BRN/WHT 47-6
OIL PRESSURE
ORN/RED 49-53
SENSOR
BRN/WHT 47-5
11
WHT/YEL 48-3
WHT/YEL 48-9
J1-11
DEUTZ ENGINE
J1-17
J1-14
J1-15
J1-7
J1-12
BRN/WHT 47-8
MTB TO EMR2 ENGINE CONTROL

COOLANT 2 8 GRD(TempAll)
TEMPERATURE
1 9 ADC7(TEMP3) 1
EMR2 ENGINE CONTROL TO ENGINE
ENGINE 2 13 SPEED 2
SPEED
1 12 GRD (SPEED)
CAMSHAFT 10
1 23 GRD (ACD2)
11
CHARGE AIR2 4 ADC5(TEMP1)
PRESSURE 3 25 +5Vref(ADC2) 12
4 24 ADC2
13
1 22 +5Vref(ADC4)
ENGINE OIL 14
2 21 ADC4
PRESSURE
3 20 GND (ADC4)
1 14 ActorOut
EMR 2 15 ActorOut
YEL/RED 2-1-99 (16)
ACTUATOR 3 17 RackMeasCom
4 19 RackMeasSignal
5 18 RackMeasRef
120 OHM
J1-22
RESISTOR
CAN SHIELD
CAN LO
CAN HI
BLACK (16)
ORN/RED 49-198
ORN/RED 49-199
YEL/RED 2-1-98
BLACK 0-1
GM ENGINE
BLACK (18)
RED (18)
BLU/ORN 52-5
5 AMP
7500 W
GENERATOR
GENERATOR
CONTROL
B+ BOX B L K A
C
B
A
J1-8
B A C
12 VDC
CONNECTOR
SEE SHEET 1
7
DEUTZ
IGN POWER
SEE SHEET 1
BATTERY DIANOSTICS
PLUG
BLU/ORN 52-6
YEL/RED 2-20
BLACK
BLU/ORN 52-5
87 87a
86 85
30
87 87a
86 85
30
RED RED
1870215 D
3121180 – JLG Lift – 7-25

WHT/LT GRN
D GASOLINE
LT GRN/RED SENSOR TWR
C
LT GRN/WHT WHT/RED A LPG TEMP.
B WHT/BLK A
BLK/LT GRN BLK/LT GRN
A B PNK/TAN LOCKOFF
B
1 DR GRN/ORN
EGO 1
2 DR GRN/WHT
EGO 2
3
EGO 3
4
EGO 4
5 PUR/LT BLU
TPS 1
6 LT BLU/DK BLU
TPS 2
7 LT GREEN
MAP
8 TAN/DK GRN
AUX ANA PDI
9 DR BLU/ORN
FPP 1
10 PUR/YEL
FPP2/1VS
11
AUX ANA PD2
12
AUX ANA PD3
13 WHT/ORN
CAN1 TERM +
14 BLU/PNK
CAN1 +
15 BLU/WHT
CAN1 -
16 CRANKSHAFT
CAN2 -
17 POSITION
CAN2 +
18
CAN2 TERM +
19 LT GRN/RED PUR/WHT A
5V EXT 1
20 BLK/LT GRN WHT/PUR
5V EXT B
21 PUR/WHT
CRANK +
CRANK - 22 WHT/PUR
23 GRY/BRN
CAM +
24 PUR/ORN
CAM -
25 RED/WHT
ROAD SPEED +
26 RED/BLK
ROAD SPEED -
27
KNOCK1 +
28
KNOCK1 -
29
KNOCK2 +
30
KNOCK2 -
31 YELLOW
SPK COIL 1A
32
SPK COIL 1B
33
SPK COIL 2A
34
SPK COIL 2B
35
SPK COIL 3A
36
SPK COIL 3B
37
SPK COIL 4A
38
SPK COIL 4B
39 YEL/GRY
1AT
40 TAN/WHT
ECT
41 WHT/RED
LP TEMP
42 TAN/BRN
AUX DIG 1
43 TAN/RED
AUX DIG 2
44 TAN/BLK
AUX DIG 3
45 PNK/TAN
VSW
46 DR BLU/YEL
AUX ANA PU1
47 YEL/DR BLU
AUX ANA PU2
48 LT GRN/WHT
AUX ANA PU3
49 LT GRN/PUR
(FPP 2 ONLY) 5V EXT 2
50 LT GRN/BLK
5V RTM
51 GRY/DR BLUE
GOV1
52 GRY/ORN
GOV2
53 LT BLUE
OIL PRES
54 WHT/LT GRN
(FRP) AUX ANA PUD1
55 DR GREEN
PC TX
56 ORANGE
PC RX
57
PULSE IN
58 GRAY
TACH
59
EPR PWR
60 RED/TAN IGNITION
VBAT
61 BRN/LT BLU COIL
INJ1 LS
62 BRN/ LT GRN PNK/DR GRN
INJ2 LS A
63 BRN/YEL YEL/BLK
INJ3 LS B
64 BRN/WHT PLUG
INJ4 LS C
65
INJ5 LS
66
INJ6 LS
67
INJ7 LS
68
INJ8 LS
69 BLACK 16
GROUND
70
STARTER
71 WHT/LT BLU
RELAY
72 BLK/WHT
EGOH 1
73 BLK/YEL
EGOH 2
74
EGOH 3
75 WHT/BLK
LOCKOFF
76
BUZZER
77 BRN/WHT
PWM5
78 WHT/BRN
PWM5 RECIRC
79 RED/TAN
VBAT
80 GRN/YEL
MIL
81 BLACK 16
GROUND
82 PNK/WHT
DBW +
83 TAN/ORN
DBW -
84 TAN/BLK
FUEL PUMP RELAY
85 PNK/YEL
AUX PWM3 RECIR
86 BLK/RED
(FUEL PUMP) PWM3
87 TAN
AUX PWM1
88 DR BLUE
AUX PWM2
89 PNK/BLK
AUX PWM3
90 BLK/LT GRN TWR
AUX PWM4 RECIR PUR/ORN
A
GRY/BRN CAMSHAFT
B POSITION
LT GRN/RED C
NOTE: This Schematic covers machines built PUR/LT BLU

6
S/N 1300002604 to Present. LT BLU/DR BLU
PNK/WHT
5
4 BOSCH
LT GRN/RED THROTTLE
3
BLK/LT GRN 2
TAN/ORN
1
BRN/YEL BRN/LT BLU
BRN/WHT
BRN/ LT GRN
PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16
7-26 – JLG Lift – 3121180

BLK/YEL BLK/WHT
D EGO 2 D
BLK/LT GRN BLK/LT GRN
C C
PNK/DK GRN PNK/DK GRN EGO 1
B B
DR GRN/WHT DR GRN/ORN
A A
TAN/WHT A
BLK/LT GRN ECT
B
C
LT GREEN
4
LT GRN/RED 3 BOSCH
YEL/GRY 2 TMAP
BLK/LT GRN CONNECTOR 2
1
PINK/DR GRN S 12V RELAYED POWER

TAN/DR GRN R AUX ANA PD1
RED/BLK P VS-
RED/WHT N VS+
TAN/BLK M AUX DIG 3
TAN/RED L AUX DIG 2
GRY/DR BLU K GOV SELECT 1
LT BLUE J GOV SELECT 2
GRY/ORN
DR BLU/YEL H AUX ANA PU1
OIL PRESS.
BLACK YEL/DR BLU G AUX ANA PU1
SWITCH
TAN 18 F AUX PWM 2
BLACK 16 E GROUND
GRAY D TACH
BRN/WHT 16 C AUX PWM 5
BLACK (12) WHT/BRN 16 B AUX PWM 5 RECIRC
GROUND
A AUX PWM 1
TAN 16 VEHICLE INTERFACE CONNECTORS
LT BLU/PNK 16
CONNECTOR 1
LT GRN/PUR S 5V EXT 2 (FPP2 ONLY)

LT GRN/BLK R 5V RTN 2
BLU/WHT P CAN1 -
BLU/PNK N CAN1 +
LT GRN/RED M 5V EXT 1
BLK/LT GRN L 5V RTN 1
DR BLU/ORN K FPP1
PUR/YEL J FPP2/1VS
TAN/BRN H FUEL SELECT (AUX DIG)
GRN/YEL G MIL
LT BLU/PNK 16 F START IN (INTERRUPT TYPE)
DK BLU 18 E START IN (AUTOCRANKING)
PNK/YEL 16 D FUEL PUMP +
BLK/RED 16 C FUEL PUMP -
PURPLE 16 B ALT EXCITE
87a
30 PINK A VSW
WHITE 16
87 RED/TAN 16
LT BLU/PNK
86 START RELAY
DIAGNOSTIC
CONNECTOR
PNK/BLK 85
BLK/LT GRN 1 ANA RTN

LT GRN/RED 2 5V REF
DR GRN 3 PC TX
ORANGE 4 PC RX
5 UNUSED
6 UNUSED
BLU/PNK 7 CAN +
FUEL PUMP
BLU/WHT 8 CAN1 -
PNK/DR GRN 16 F5 PNK/YEL 16
15A
PNK/TAN F1 PINK
5A
VSW
D RED/TAN 16 F6 RED 16 60A
BLACK 16 RED 10
C IGNITION 15A
YELLOW B MODULE MAXI FUSE
STARTER
PNK/DK GRN A
RED 10
ALTERNATOR B+
RED/TAN 14 F2 RED 14 RED 12
20A
PNK/DR GRN 16 F4 PNK/DR GRN 16 ECM
15A B+ RED 16
A ALTERNATOR
IGNITION STARTER PURPLE 16
B
PNK/DR GRN 16 SOLENOID
RED 16 STARTER
MOTOR
WHT/LT BLU 85
RED 16 30 SEE SHT-2 BLACK 10
PNK/DR GRN 14 87 FOR BATTERY
RED/TAN 86 CONNECTION
GROUND
POWER RELAY ALTERNATOR -
TAN/BLK 85
EPR PNK/YEL 16 87
CONNECTOR RED 16 30
PNK/TAN 86
BLU/WHT 1 CAN -
WHITE 2 CAN + FUEL PUMP RELAY
BLU/PNK 3 CAN +
4 UNUSED
5 UNUSED
BLACK 16 6 GROUND
RED/LT BLU 16 7 VBAT
8 UNUSED
EPR FUSE
RED/LT BLU 16 F3 PNK/DR GRN 16
10A
1870215 D
3121180 – JLG Lift – 7-27

Figure 7-36. Electrical Schematic 1001141989 - Sheet 1of 4 (LH)
7-28 – JLG Lift – 3121180

Figure 7-37. Electrical Schematic 1001141989 - Sheet 1of 4 (RH)
3121180 – JLG Lift – 7-29

Figure 7-38. CAT/Perkins Engine Electrical Schematic 1001141989 - Sheet 2 of 4 (LH)
7-30 – JLG Lift – 3121180

Figure 7-39. CAT/Perkins Engine Electrical Schematic 1001141989 - Sheet 2 of 4 (RH)
3121180 – JLG Lift – 7-31

Figure 7-40. Deutz Engine Electrical Schematic 1001141989 - Sheet 3 of 4
7-32 – JLG Lift – 3121180

Figure 7-41. GM/PSI Engine Electrical Schematic 1001141989 - Sheet 4 of 4
3121180 – JLG Lift – 7-33

Figure 7-42. Electrical Schematic 1001102901(LH)
7-34 – JLG Lift – 3121180

Figure 7-43. GM/PSI Engine Electrical Schematic 1001102901 (RH)
3121180 – JLG Lift – 7-35

Figure 7-44. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (LH)
7-36 – JLG Lift – 3121180

Figure 7-45. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (RH)
3121180 – JLG Lift – 7-37

7-38 – JLG Lift – 3121180

3121180 – JLG Lift – 7-39

7-40 – JLG Lift – 3121180

3121180 – JLG Lift – 7-41

Hydraulic Drawing 1283460 Description
Figure 7-50. Hydraulic Schematic 1283460 - Sheet 1 of 7 (RH)
7-42 – JLG Lift – 3121180

3121180 – JLG Lift – 7-43

Figure 7-52. Hydraulic Schematic 1283460 - Sheet 2 of 7 (LH)
7-44 – JLG Lift – 3121180

3121180 – JLG Lift – 7-45

7-46 – JLG Lift – 3121180

3121180 – JLG Lift – 7-47

7-48 – JLG Lift – 3121180

3121180 – JLG Lift – 7-49

Figure 7-58. Hydraulic Schematic 1283460 - Sheet 5 of 7
7-50 – JLG Lift – 3121180

Figure 7-59. Hydraulic Schematic 1283460 - Sheet 6 of 7
3121180 – JLG Lift – 7-51

7-52 – JLG Lift – 3121180

3121180 – JLG Lift – 7-53

NOTES:
7-54 – JLG Lift – 3121180

3121180
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 813058 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755 Castellbisbal, Barcelona Sweden
Spain +46 (0)850 659 500
+34 93 772 4700 +46 (0)850 659 534
+34 93 771 1762
www.jlg.com

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Service and Maintenance Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

3121180 – JLG Lift – A-1

Original Issue - January 24, 2003

A-2 – JLG Lift – 3121180

SECTION NO. TITLE PAGE NO.

3121180 – JLG Lift – i

SECTION NO. TITLE PAGE NO.

ii – JLG Lift – 3121180

SECTION NO. TITLE PAGE NO.

3121180 – JLG Lift – iii

SECTION NO. TITLE PAGE NO.

iv – JLG Lift – 3121180

SECTION NO. TITLE PAGE NO.

3121180 – JLG Lift – v

SECTION NO. TITLE PAGE NO.

vi – JLG Lift – 3121180

FIGURE NO. TITLE PAGE NO.

3121180 – JLG Lift – vii

FIGURE NO. TITLE PAGE NO.

viii – JLG Lift – 3121180

FIGURE NO. TITLE PAGE NO.

3121180 – JLG Lift – ix

FIGURE NO. TITLE PAGE NO.

x – JLG Lift – 3121180

FIGURE NO. TITLE PAGE NO.

3121180 – JLG Lift – xi

TABLE NO. TITLE PAGE NO.

xii – JLG Lift – 3121180

1.1 CAPACITIES Table 1-4. Deutz F3M1011F

3121259 – JLG Lift – 1-1

Table 1-6. Caterpillar 3024/C2.2 1.4 SPECIFICATIONS AND PERFORMANCE

Fuel Diesel Swing 357° non-continuous

1-2 – JLG Lift – 3121259

Drive (Above Horizontal): Test should be done on a

3121259 – JLG Lift – 1-3

Torque Value Torque Value Torque Value Torque Value

Oil Drain Plug 15-25 20-34 Cylinder Head Cover 6 8.5

Spark Plugs 7-15 9-20 Cylinder Head Cover 6 8.5

Pump Coupling (dry) 26.5 37 Rocker Arm Adjustment 15 21

Flywheel 54-64 73-87 Air Intake Pipe 15 21

Mechanical Governor Belt 50 222.4 Exhaust Manifold 16 22

Oil Pan (sheet metal) 15 21

Oil Pan (cast) 22 31

Pump Coupling (dry) 26.5 37

Pump Coupling (Loctite 28.5 40

Injection Line Attachment 16 22

Injection Line Attachment 21 30

Injection Valve Attachment 15 21

Lube Oil Filter Cartridge 19 27

1-4 – JLG Lift – 3121259

NOTE: Hydraulic oils must have anti-wear qualities at least to

SAE Grade 10W30 Table 1-20. Mobil EAL H 46 Specs

3121259 – JLG Lift – 1-5

1.9 PRESSURE SETTINGS - PSI (BAR)

Specific Gravity 32.1 Table 1-24. Pressure Settings

1.8 MAJOR COMPONENT WEIGHTS

Component Pounds Kilograms

1-6 – JLG Lift – 3121259